• Only trained personnel should carry out an inspection of wire ropes.
• Inspect a wire rope when installing it.
• Visually inspect wire ropes every working day and at the start of each shift.
• Keep records of daily inspections.

How do you visually inspect wire ropes?

• 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 rope. Insert a marlin spike beneath two strands and rotate to lift strands and open rope.

When should you stop using the rope and remove it from use?

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 lay length; 3 or more broken wires in one strand in one lay.
• In pendant standing ropes, 3 or more broken wires in one lay length.
• Wear of 1/3 of the original diameter of individual outside wires.
• Kinking, crushing, cutting or unstranding, bird caging or other physical damaged that has distorted the shape of the wire rope.
• Heat damage (check for burn marks, discoloration of the metal).
• Excessive stretch or sharp reduction in the rope diameter.
• Knots or splices (except eye splices) in a wire rope.

What can cause a wire rope break?

• Wear on areas in contact with hoist sheaves and drums.
• 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).
• Fatigue from repeated bending even under normal operating conditions.
• Overloading the safe working load limit. Follow manufacturers' charts.
• Mechanical abuse - crushing, cutting or dragging of rope.
• Kinks from improper installation of new rope, 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.