TECH REPORT No.

107
Wire Rope Inspection

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eriodic inspections of wire inspections. The burden of this Because different inspection
ropes in use are necessary for requirement is upon the owner/user. criteria frequently apply, so-
one very important reason: called “standing” ropes should
Wire rope is a “consumed” item. It The primary rule to follow in be inspected separately from the
is literally “used up” as it is used, conducting a wire rope inspection “running”, or operating, ropes on
and gradually loses strength during on any typical machine or piece of the same machine or installation.
its useful life. equipment is that each wire Practicalities may dictate that parts
of both running and standing ropes
The purpose be inspected on the same trip to
of an some high or inconvenient location
inspection, on an installation - regardless,
then, is each rope must be given individual
simply to attention, and the pertinent
ascertain - information on each rope must be
to such an recorded separately.
extent as may
be possible It should not be necessary to point
- whether out, but it must be emphasized, that a
a wire rope proper inspection cannot be made
retains when a wire rope is supporting a
A proper inspection requires the proper tools, the
sufficient pertinent criteria for evaluating the rope, and an load or is in motion. A rope should
capability to adequate form for recording the findings to provide be “relaxed and at rest” during the
a permanent record. inspection. An exception might
perform the
work to be be certain types of conveyor and
done before the tramway ropes.
next scheduled inspection. rope must be considered
individually. Several tools are useful in
That regular inspections are inspections:
required by certain governmental This individual treatment is
regulations is, in a sense, of particularly important when >> An awl and a marlin spike
secondary importance - since the inspecting so-called “standing” >> A caliper
need to perform such inspections ropes - those which are primarily >> A steel tape
would exist anyway. supporting, or structural, members. >> Two groove gauges
For example, the pendants which >> Chalk
But the government does require support long crane booms are >> Wiping cloths
machine owners and/or users to frequently made of several sections, >> Pencil, paper and carbon stick
conduct regular, proper inspections, each of which is an individual rope
and to keep written records of such and must be examined individually.
The manufacturer’s handbook or inspection - daily to monthly >> Pick-up Points - These are
Operator’s Manual for the machine intervals, (b) Periodic sections of rope which are
involved, and copies of pertinent inspection - 1 to 12-month repeatedly placed under stress
governmental and other inspection intervals. when the initial load of each lift is
criteria and specifications are also applied - such as those sections
useful. The foregoing would seem to in contact with sheaves.
underscore the wisdom of many
How Often to Inspect machine users who insist on a daily >> End Attachments - At each end
or work shift, visual inspection of the rope, two things must be

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uite obviously, the greater of all the elements in a wire rope inspected: the fitting that is
the usage a rope receives, system. The OSHA Regulations, attached to the rope, or to which
the more often inspections however, are specific with reference the rope is attached and the
would be indicated. Typical to written and signed reports on condition of the rope itself, where
Occupational Safety and Health Act thorough, periodic inspections. it enters the attachment.
(OSHA) regulations state:
'Critical' Points >> Equalizing Sheaves - The section
A thorough inspection of of a rope which is in contact with

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all ropes shall be made at here are certain points along and adjacent to such sheaves,
least once a month and a full any given rope which should as on boom hoist lines, should
written, dated and signed receive more attention than receive careful inspection.
report of rope condition others, since some areas will usually
kept on file where readily be subjected to greater internal >> Drums - The general condition
available. forces and hazards. of the drum, and condition of
grooves if the drum is grooved,
OSHA Specification 1926.602 refers Carefully select the most critical should receive careful inspection
to Power Crane and Excavator points for close inspection - points - as should the manner in which
Standards for material handling where failure would be most likely the rope “spools” onto the drum.
equipment as follows, regarding to occur. The same critical points
wire rope inspections (8.2.1.2): on each installation should be >> Sheaves - Every sheave in the
compared at each succeeding rope system must be inspected
All wire ropes in active inspection. and checked with a groove
service should be visually gauge.
inspected once each Critical points which should be
working day. A thorough considered for careful inspection on >> Heat Exposure - Be especially
inspection of such ropes most installations would include the watchful for signs that a rope has
should be made at least following: been subjected to extreme heat,
once a month and dated or to repetitive heat exposure.
records kept as to rope
conditions. >> Abuse Points - Frequently
ropes are subjected to abnormal
The OSHA regulations for overhead scuffing and scraping, such as
and gantry cranes states: contact with cross-members of a
boom. Look for “bright” spots.
UNION
Inspection procedure for
cranes in regular service It must be kept in mind that minor
- and frequently major - differences
ROP

is divided into two general

USA

classifications based upon exist between installations, even

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the intervals at which on machines of a similar design.

inspection should be Therefore, points on each rope
performed, designated as selected for close examination
‘frequent’ and ‘periodic’ with will necessarily require the best
respective intervals between judgement of the inspector.
inspections ... (a) Frequent
End Attachments Measuring Diameter >> Normal Wear -
In normal usage, the outer

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ll end attachments have very periodic inspection wires, particularly on the crowns
one characteristic in must include diameter of strands, will exhibit wear.
common: all restrict, to measurement at Various inspection standards
some degree, the free movement critical points - and recording are specific as to the amount of
of the wires at the end of the rope. of measurements for future such metal loss permissible.
This impairment can ultimately comparisons.
result in breakage of wires at the >> Internal Rope Damage -
point where restriction occurs. Most inspection standards are When the core of a wire rope
specific on permissible reductions has begun to deteriorate,
Broken wires are a primary concern in diameter, and the criteria for diameter reduction is often the
when inspecting end attachments the installation and industry first detectable outward sign.
on a rope. A single broken wire involved should be known by the Impending internal breakdown
is usually reason to question inspector before starting to take should always be suspected
continued use of measurements. when a sudden or significant
the rope, and more than one is diameter reduction is noted,
usually sufficient cause for rejection. Measurements are proper only and if possible, an internal rope
when made across the “crowns” examination should be made.
of rope strands, so that the true
diameter is the widest diameter Measuring Rope Lay
at any given point on the rope.

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Always rotate the caliper on the ne rope lay is the length
rope - or the rope inside the caliper along the rope which a
- to take a measurement. single strand requires
to make one complete spiral, or
“turn”, around the core. It is an
engineering factor in the design of
a rope, and is carefully controlled
An awl used to probe the point where strands during manufacture.
enter the end attachment can often expose broken
wires.

Since there is often some

Broken wires may be more difficult “adjustment” in rope lay during the
to locate at end fittings than in other initial “break-in” stages of a rope’s
sections of rope. An awl used to The correct method used to accurately measure usage, it is recommended that
pick and probe at the point where wire rope diameter.
rope lay measurements should be
strands enter the end attachment made after the initial loading, for
can often expose broken wires not Reductions in diameter are caused comparison purposes at succeeding
otherwise visible. by several factors, including: periodic inspections.

Another problem frequently >> Initial “Pull-Down” -

encountered at end fittings is All ropes are manufactured
corrosion or rust. Such corrosion larger than nominal diameter.
can easily conceal broken wires, and When placed in operation
if left to accumulate can erode the the first time, strands of a
surface of wires to weaken them, or new, unused, rope will “seat
can restrict normal wire movement. in”, and the diameter will be
“pulled down” from its original
Inspection of rope ends should also diameter. Therefore, the first
include the condition of the actual measurements should be
attachment - worn eyes, missing made and recorded for future
thimbles, bent or “opened” hooks, reference after the time of such This image simulates 6x25FW construction wire
worn clevis pins, and so on. a rope’s initial loading. ropes with surface wear (only) of 1/3 the outer
wire diameter.
One method for measuring rope lay Unlaying sometimes results from easily observed. It is important that
is with a carbon stick and blank operating a rope without having a diligent search be made for broken
white paper. Firmly hold the paper both ends secured to prevent wires, particularly in critical areas
on the rope and “stroke” with the rotation. An end swivel attachment such as “pick-up points" where
carbon stick, so the rope’s “print” is permits such rotation and unlaying. stresses are concentrated.
made on the paper.
Another common cause of unlaying The first step in looking for broken
By drawing a line through one is worn sheaves. When the bottom wires is to make sure the surface
strand of the “print”, counting off of a sheave groove wears, it can is clean enough that breaks can
the number of strands in the rope restrict normal movement as the be seen. Wipe with a cloth. If
and then drawing another line rope enters and leaves the groove; necessary, scour with a wire brush
on the print at the place where the result can be a build-up of twist to clean grease from the valleys
the same strand appears again, a which can change the length of lay. between strands.
measurement is established.
Whatever the cause, unlaying is an A thorough search for broken wires
abnormality, and should be noted cannot be made when a rope is in
for future reference if the immediate tension or is supporting a load.
cause cannot be determined. Relax the rope, move “pick-up
points” off sheaves, and flex the
rope as much as possible.
Finding Broken Wires
With a sharp awl, pick and probe

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robably the most common between wires and strands, lifting
sign of rope deterioration and any wires which appear loose or
An example of one method to accurately
measure rope lay, using carbon paper, blank approaching failure is broken move excessively.
white paper, and a pencil. wires, and inspection criteria are
specific as to the number of broken
Many inspectors have found that a wires allowable under various
crayon or marking stick and a roll of circumstances.
adding machine tape are ideal for
making a “print” at last three rope
lays long - so that an average lay
length can be determined.
Changes in length of lay are usually Under ideal and normal conditions, wires should
break first on the crowns of the strands...as in this
gradual throughout the working life classic example of a worn out rope.
of a rope. It is important to compare
current lay measurements with Flexing a rope can often expose broken wires
previous inspection results to note hidden in valleys between strands.
any sudden changes - for an abrupt If you find a number of broken
change in the pattern can be the wires approaching the maximum
signal of an impending problem. It is normal for a properly designed allowable permitted per strand or
and used “running”, or operating, per rope lay, extend the search
As a rule, if lengthening of lay is rope to exhibit broken wires as it to other sections of the rope,
noted WITH loss of rope diameter, approaches the end of its useful and also take diameter and lay
internal break-up or core destruction life. Under ideal conditions, the measurements in the area. If
should be suspected. first wires to break would be the internal wire breaks or core
When lengthening of lay is noted outside wires at the crowns of the damage are suspected, an internal
WITHOUT loss of rope diameter, the strands - where surface wear is examination should be made, if
rope is probably “unlaying” for some expected to occur. On “standing” possible.
reason, and further examination ropes, wire breakage may not be so
should be made for the cause.
Making an Internal Rope In the case of fiber core ropes, Assessing the general physical
Examination examine the core for excessive condition of a sheave - groove
breakage of fibers. If short pieces of smoothness, freedom from cracks

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ny time interior damage, fiber - less than 1/4 inch long - sift and "nicks", existence of wear on
broken wires or core failure out of the core, it is breaking up. guards, etc. - is a matter of careful,
may be suspected, a Such short, broken fibers sometimes knowledgeable observation.
section of rope should be opened for indicate the rope is being over-
internal examination. This may be loaded, pinched in tight sheaves, or Properly gauging and evaluating the
accomplished without destroying subjected to other abuse. width, depth and contour of grooves
the rope's future usefulness if due with a groove gauge requires keen
care is exercised and wires are not If a rope has been opened properly observation as well as knowledge of
kinked or notched. and carefully - and internal gauge design and use.
condition does not show cause for
removal - strands can be returned There are two types of wire rope
to their original working positions groove gauges:
without distorting the rope or
impairing future usefulness. 1. Those used by
manufacturers of sheaves
Inspecting Sheaves and drums, which make
allowance for the maximum

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lmost every rope installation allowable oversize for
has one or more sheaves wire rope, and are used
- ranging from traveling to determine the proper
blocks with complicated reeving contour for NEW grooves.
patterns to equalizing sheaves
where only minimal rope movement 2. Those used "in the
is noticeable. Each sheave should field", which are made to
receive an individual examination at the nominal diameter of
periodic inspections. the rope PLUS one-half the
allowable rope oversize.
Each sheave is to be examined for These are used to determine
the following: the MINIMUM condition for
To open a rope, insert a marlin spike beneath two WORN grooves.
strands and rotate to lift strands and provide view >> Groove depth, width and
of interior. In a field inspection, when the
contour
>> Groove smoothness gauge for worn grooves fits
A rope can be opened for internal >> Broken or chipped flanges perfectly, the groove is at the
inspection only when completely >> Cracks in hubs, spokes, etc. minimum permissible contour.
relaxed. Using due care, "work" a >> Signs of rope contact with Anything narrower is unsuitable for
marlin spike beneath two strands guards use.
and rotate the spike to expose the >> Sheave bearings and shaft
core and "under" side of strands. >> Out-of-round condition It is a good rule to keep in mind
Use an awl to probe for broken wires >> Alignment with other sheaves that, under normal operating
and examine inner surface. conditions, as a groove wears
it tends to become deeper and
If the rope has an independent wire narrower. Excessive wear in an
rope core, look for broken wires on over-width manner frequently
the "under" sides of strands where indicates some operating
the strands contact the IWRC. Look abnormality such as alignment.
for excessive "nicks" or broken A proper fitting
wires in the strands caused by sheave groove
should support
contact between adjacent strands
the rope over
or with IWRC. Examine the IWRC 135-150
for broken wires also. degrees of rope
circumference.
 and checked with a groove gauge spaces at the top of the form. These
if normal tolerances apply. Bottoms identify the machine or installation,
of grooves should be smooth; its owner, location, date, etc.
drums that become imprinted with "Rope Application" refers to the
the rope's "tread", or excessively specific usage of the rope...such as
roughened, should be corrected or "Main Hoist", or "Boom Pendant", or
replaced. Grooves should be spaced "Boom Hoist".
so one wrap of rope does not "scrub"
the next wrap as it spools onto the After "Rope Description", fill in the
drum. diameter, construction, type, etc
Observe the groove so that it may be clearly seen
whether the contour of the gauge matches the ...such as 1 in. 6x25 FW PRF RLL
contour of the bottom of the groove. Spooling is that characteristic of XIP IWRC.
a rope which affects how it wraps
onto and off a drum. Spooling is After "Manufacturer's Ident. No.",
Sheave inspection should also affected by the care and skill with insert data which will positively
include the condition of bearings which the first layer of wraps is identify this rope...preferably the
and shaft. With the rope "relaxed", applied on drums with two or more manufacturer's "reel number" which
the sheave should be rotated by layers. Wraps should be tight, and a identifies the reel from which the
hand to determine the "fit" of the loose condition must be corrected. rope was taken. The manufacturer's
bearing and effectiveness of its original purchase invoice or the
lubrication...whether the sheave It is important to examine a rope shipping reel tag usually carries this
runs true, without "wobbling" on for kinks or other damage when number.
its shaft...whether the bottom of loose or irregular spooling has been
the groove is still concentric, or observed. The "Applicable Standards" refer
"round" in relation to the shaft... to the set of inspection criteria
and whether the sheave and its Drum Crushing is a rope condition applicable to this installation which
shaft are in proper alignment with sometimes observed which can be found in standards and
other sheaves or components of the indicates deterioration of the rope. regulations...such as ASME B30.2
system. Sometimes crushing is inevitable for Overhead & Gantry Cranes or
on a given drum winding, as is Federal Regulations such as OSHA.
deformation of the wires in the
Evaluating Drums rope, usually described as peening. It is the inspector's responsibility to
Crushing and peening affect rope obtain the proper inspection criteria

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nspection criteria for drums will performance to such an extent as for the application to be inspected.
usually specify the following: these conditions impair adjustment
of wires in the rope and damage the At the column headings to the right
>> Minimum number of dead wires themselves. When observed, of the words "Criteria for Removal",
wraps to remain on the drum either condition should be noted space is provided for the inspector
>> Condition of drum grooves, if a and careful evaluation of rope made. to fill in specific criteria pertaining
grooved drum, and the surface to each column. Fill the blank
of a smooth drum spaces with data taken from the
>> Condition of flanges at the ends How to Use Inspection Forms proper set of criteria for the machine
of the drum involved.

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>> Rope end attachments hese forms were prepared A blank column is provided for
>> Spooling characteristics of the to serve as a guide for inspector's use if it is desirable to
rope making thorough periodic check any other factor which is not
>> Rope condition, particularly at examinations of single wire ropes listed on this form.
"pick-up points" on the rope and serve as a permanent record
of the inspection. One form should At the time of each inspection of an
There is wide acceptance of the be used for each rope at each such installation, refer back to previous
following guidelines for checking inspection. inspection records to determine
drums and drum operation. locations on each rope which should
Before beginning an examination be inspected. If the installation
Grooves should be of proper contour, of an installation, fill in the blank has not previously had a thorough
inspection, sound judgement should 5. A lay measurement should also To provide space for all these
be used in selecting these locations. be taken at the location selected measurements, five horizontal
"Critical Points" should be given for inspection. spaces are provided on each
first consideration. 6. Examine the entire rope end- Inspection Report form. Should
to-end for evidence of external these not be sufficient for extremely
The same locations on each rope damage or abuse. Where long ropes, or for any other reason,
should be examined carefully damage or abuse is noted, these spaces may be divided with
at each succeeding inspection proceed to make all the same horizontal lines - or a second form
so that rope diameter, lay, etc., observations for this location used.
may be compared to previous as at any "regular" inspection
measurements in order to detect point. Try to determine the When an inspection is completed -
change in the rope condition. exact cause of any external or has proceeded far enough for the
Sudden changes in condition may damage so that "recurring" inspector to decide that rejection is
indicate deterioration. damage may be prevented. in order - the form should be signed
by the inspector. Comments may
At each inspection location on a 7. Every sheave should receive a also be written at the bottom, if
rope, clean the rope sufficiently to thorough examination and the desired.
be able to find broken wires and condition recorded. When the
to take precise measurements. To rope "pick-up point" is being Federal regulations require that
be useful, measurements must be examined at a sheave, the data signed inspection reports must be
accurate. on the sheave can be recorded maintained on file for all ropes in
at that space on the form. active service.
For each inspection location 8. Examine and record the
selected on each rope, describe drum condition. In a proper
on the Inspection Report the inspection, the drum should
exact location - such as "boom be observed both in operation
point sheave at pick-up". Then, and at rest in order to observe
in the order in which columns are "spooling".
established on the report form,
make the indicated observations
and write down the information:

1. Measure diameter
2. Examine for broken wires, (a)
in one rope lay, and (b) in one
strand of one rope lay. When
a broken wire is found, look
carefully for others. Record
the number of breaks in that
rope lay where the most
breaks are found.
3. At this same location,
inspect for excessive
wear.
4. If the
examination is
being made at a
rope dead-end, check for
broken wires, corrosion and
condition of the fitting.
Use a Wire Rope Inspection Report
to maintain accurate record of all wire
rope inspections.
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ngineering wire rope for Our manufacturing standards So look to the best: The Union
your application is a highly typically exceed the minimum brand back by the WireCo
specialized field - with design standards for a wire rope. WorldGroup organization. We're
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live by. Across the entire WireCo associations that develop wire rope advancing wire rope to your
WorldGroup organization, we draw specifications and standards, such dynamic applications throughout
from our global pool of talented as ASTM A1023. the world.
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application. We apply thorough design and With a global manufacturing and
manufacturing controls - including distribution base, along with our
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