Wire rope inspection is the regular examination of steel wire ropes on cranes, hoists and slings for broken wires, wear, corrosion and other damage to decide whether they are safe to keep in service.
Wire rope inspection is the examination of steel wire ropes to find damage and deterioration before it leads to failure. Wire ropes are used on cranes, hoists, winches, elevators and slings, and they wear out with use. Broken wires, abrasion, corrosion, crushing, kinking and heat damage all reduce a rope's strength, often without obvious warning.
Inspections range from quick visual checks before each shift or use to detailed periodic examinations by a qualified person. The inspector compares what they find with removal criteria set by OSHA, ASME standards and the rope or equipment manufacturer to decide whether the rope can stay in service.
OSHA's crane standard at 29 CFR 1926.1413 requires:
Under 29 CFR 1910.184 and ASME B30.9, slings and their fittings must be inspected each day before use by a competent person, with additional periodic inspections based on how often and how severely they are used.
Under ASME B30.5 and OSHA's crane rules, ropes should be removed from service when inspectors find, among other conditions:
Under 29 CFR 1910.184(f), wire rope slings must be removed from service for ten randomly distributed broken wires in one rope lay, or five broken wires in one strand in one rope lay, as well as for wear of one-third of the original diameter of outside wires, kinking, crushing, birdcaging, heat damage, cracked or distorted end attachments and corrosion of the rope or fittings.
During a monthly inspection of a mobile crane on a construction site, the competent person noticed a short section of the hoist rope that looked flattened where it ran over the boom tip sheave. Counting closely, he found three broken wires in one strand within one lay, which met the removal criteria.
The crane was tagged out until the rope was replaced. The investigation found that a worn sheave groove had been pinching the rope. The sheave was replaced along with the rope, and the contractor added sheave groove gauging to its annual inspection checklist. The removed rope section was kept for training so operators could see what early damage looks like before it becomes a dropped object hazard.
Shift and daily checks are done by a competent person, someone able to identify hazards and with authority to correct them. Annual and more detailed inspections of crane ropes must be done by a qualified person.
A rope lay is the length along the rope in which one strand makes one complete turn around the core. Broken wire limits are usually counted within one lay.
Sometimes, if the remaining rope is long enough and undamaged and the ends are properly terminated, but this must be done according to the manufacturer's and standard's requirements. Otherwise, the rope should be replaced.
Yes. Lubrication reduces internal wear and corrosion. Follow the rope manufacturer's guidance on lubricant type and frequency.
Part of SafetyIQ's EHS glossary: plain-English definitions of workplace health and safety terms.
> Keep learning
> See it in action
Capture hazards, run inspections, track training and close out corrective actions in one platform built for high-risk, field-heavy work.
Book my free demo
Get a demo built around your sites, your teams, and the way your people work.
EHS, journey, and fatigue management software for field-heavy teams.
.png){kind=logo}
.png)