Wire ropes are one of the most used materials in the industrial world. In 2020, the production volume of steel wire ropes in Japan was about 240.32 thousand tons, according to Statista. Wire rope sling manufacturers are using their products more and more in marine environments or for rigging purposes. But wire ropes are subjected to heavy loads, and they suffer a lot of mechanical damage.
According to the top steel wire rope manufacturers, some of the most common reasons wire ropes fail are corrosion, excessive wear, misuse, and lack of maintenance, which leads to reduced safety, increased replacement costs, and early disposal. Want to know how the pros do it? Here’s how steel wire rope manufacturers inspect wire ropes.
How often should you inspect your wire ropes?
You need to visually inspect all wire ropes every day before you start using them. This is a safety rule that can keep you safe. While it is difficult to determine the exact service life of a wire rope, if you look at it more often, you will get a better idea of how long it will last. Also, keep in mind that if you can figure out exactly how long the wire rope has been in service under the mooring/tidal conditions, load pressures, etc., that may be the answer. You need to have a competent person do a complete, thorough periodic inspection of the wire rope.
How do you visually inspect a wire rope?
You can check the condition of the wire rope by doing a standard inspection. Look for:
Wire breaks (Pro tip: Valley wire breaks are worse than outer wire breaks.)
Abrasion damage from going over the drum and sheaves during normal use
Corrosion from lack of lubrication. (Pro tip: Look for discoloration.)
Reduction in diameter from excessive abrasion under normal load conditions
Crushing or flattening of wire rope strands
High stranding
Shock-loading or bird-caging from suddenly releasing tension on the wire rope and overloading it.
The rag and visual method
You can use the rag-and-visual process to check for any external damage. All you need to do is grab the rope lightly with a rag or cotton cloth. Then move the rag along the wire, and if there are any broken wires, they will stick out and snag on the rag. If the rag catches broken wires, you can stop and look at the rope. Also, make sure to look at the wire without any rag because some wire breaks don’t stick out.
Eyeball the rope diameter
Eyeball the rope diameter and compare it to the original numbers. If the measurements don’t match, something’s wrong with the rope inside or out.
Check for wear
When a steel wire rope passes over a drum and sheaves or any other metallic equipment component, wear occurs. Therefore, it is important that all components are in good working order and the proper diameter for the rope. A badly grooved or worn sheave or drum will tear up a new rope, causing you to replace it before its time.
Also, look for rust, pits, wear, end fitting conditions, broken wires (if any), and lubrication inside the rope. Inspect the wire rope for anything that doesn’t look right, such as External damage, Kink, Strand looseness, Core protrusion, or Bird-caging.
Always keep inspection records so you can tell how the rope is doing the next time you inspect it.
Word of caution
Sometimes you can see the damage on the outside, but sometimes the break is inside the wires. So make sure you have your slings made and inspected by people who know what they’re doing. Looking for the best wire rope sling manufacturers and inspection company that is very strict on quality? IVITALRIGGING is your answer!
