INFORMATIVE PUBLICATION 10/I

WIRE ROPES FOR LIFTING APPLIANCES.

GUIDELINES FOR CONDITION ASSESSMENT

January
2022

Publications I (Informative) are issued by Polski Rejestr Statków S.A.

as guidance or explanatory notes to PRS Rules

GDAŃSK
Informative Publication No. 10/I – Wire Ropes for Lifting Appliances. Guidelines for Condition Assessment – January
2022 was accepted by the Director for Ship Division of Polish Register of Shipping S.A. on 21 January 2022.
This Informative Publication replaces the Informative Publication No. 10/I – Wire Ropes for Lifting Appli-
ances. Guidelines for Condition Assessment – 2016.

© Copyright by Polish Register of Shipping*, 2022

PRS/RP, 01/2022
 CONTENTS
Str.

1 Introduction .................................................................................................................................................... 5
2 Wire Ropes Examination and Tetsting ......................................................................................................... 5
2.1 General examination ................................................................................................................................ 5
2.2 Close-up examinations ............................................................................................................................. 6
2.3 Testing of rope terminations .................................................................................................................... 6
3 Criteria for the Assessment of Wire Ropes Wear ........................................................................................ 7
3.1 Number of cracked wires in the rope ....................................................................................................... 7
3.2 Broken wires at rope termination ............................................................................................................. 8
3.3 Localized grouping of broken wires ........................................................................................................ 8
3.4 The rate of increase of broken wires ........................................................................................................ 8
3.5 Fracture of strands.................................................................................................................................... 8
3.6 Reduction of the rope diameter due to core deterioration ........................................................................ 8
3.7 Decreased rope elasticity ......................................................................................................................... 8
3.8 External and internal wear ....................................................................................................................... 9
3.9 External and internal corrosion ................................................................................................................ 9
3.10 Wire rope deformation ........................................................................................................................... 10
3.11 Damage due to heat or electric arcing .................................................................................................... 11
Attachment 1 Diagrammatic Illustration of Possible Defects to be Considered During Examination .............. 12
Attachment 2 Internal Examination of Wire Rope ............................................................................................ 13
Attachment 3 Wire Rope Examination Record ................................................................................................. 15
Attachment 4 Typical Examples of Defects Thay May Occur in Wire Rope .................................................... 17
Informative Publication 10/I
Wire ropes for lifting appliances. Guidelines for condition assessment January 2022

1 INTRODUCTION
A wire rope on a lifting appliance is regarded as a wearing element, requiring replacement when
the results of inspection indicate that its condition has diminished to the point where further use
would be unwise from a safety standpoint. The rope lifetime depends on the lifting appliance
workload, the rope technical condition and intended use, and on environmental operational con-
ditions.
The safe handling of loads may be ensured through periodical examinations of ropes, so that they
are removed from service in adequate time. The examinations of wire ropes apply, irrespective of
operational conditions, the wear criteria, taking into account the number of broken wires, the rope
abrasion, corrosion and deformation.
The mentioned criteria are described in this Publication, aimed at checking safety reserve of op-
erated wire ropes and determining their safety margin, after transgressing of which the rope
should be discarded. Failure to recognize them can be dangerous for the users of lifting appliances.
The below specified principles may be also applied to wire ropes used in appliances other than
used for lifting, but with similar type of operation.
The new issue of Publication 10/I is based on the below standards:
− PN-EN 12385 – 1 Steel wire ropes – Safety – Part 1: General requirements 2008/2009.
− PN EN 12385 – 2 Steel wire ropes – Safety – Part 2: Definitions, designation and classification
− PN EN 12385 – 3:2021-5 Steel wire ropes – Safety – Part 3: Information for use and mainte-
nance
− PN EN 12385 – 4 Steel wire ropes – Safety – Part 4: Stranded ropes for general lifting applica-
tions;
− ISO 4309: 2010 – Cranes – Wire ropes – Care and maintenance, inspection and discard;
− ISO 17558:2006(en) - Steel wire ropes — Socketing procedures — Molten metal and resin
socketing
and reports:
− HSE OTH 341 – Wire rope offshore – review of wire rope endurance research affecting offshore
applications;
− HSE OTO 2000 064 – Wire rope Non-Destructive Testing – Survey of Instrument Manufactures
− HSE OTO 2000 069 - Resin-Socketed Termination of Offshore Wire Ropes

2 WIRE ROPES EXAMINATION AND TETSTING

2.1 General examination
The wire rope shall be examined along its whole length, taking into account the following portions:
− sections at the ends of ropes – both the winding and the fixed ones (stays, preventer guys,
shrouds);
− sections of wire ropes winding under load over pulleys or pulley blocks (See Attachment 1);
− sections of wire ropes wound over the compensating pulley;
− sections subjected to abrasion by contact with external elements (e.g. hatch coaming);
− sections particularly subjected to corrosion and fatigue (see Attachment 2);
The user shall maintain the Wire rope examination record and make there entries on the examina-
tion results (example of such Record is given in Attachment 3).

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2.2 Close-up examinations

2.2.1 Close-up assessment of technical condition of wire ropes for detection of invisible dam-
ages or corrosion may be performed with the use of NDT techniques able to detect internal dam-
ages in the rope (such as cracked wires), with the magnetic inspection (MRT) being the most fre-
quently applied.
2.2.2 The Magneto-Inductive Rope Testing (MRT) includes: generating strong magnetic field
acting on structural material of rope for its magnetization to reach full saturation (> 1.9 Tesla),
the measurement of magnetic field and its changes and processing of collected information into usable
format. The testing is executed with a speed up to 4 m/s and the results may be currently visualized,
documented and analyzed, in accordance with the requirements for the given supervision.
2.2.3 Damages inside the rope result in the dispersion of magnetic field, which is measured for
the whole rope or for its selected portions. The method enables detection of a number of damages
at early stage of their occurrence and propagation, e.g.:
− internal and external broken wires
− internal and external corrosion
− clamping points
− grooves
− notches
− structural changes
2.2.4 The method enables detection, analysis and monitoring of the condition of the rope struc-
ture both of small and large diameter, e.g. from 4 to 140 mm. The assessment methods include
simultaneous visual assessment and are used for current assessment of wire rope technical con-
dition for its safe operation. The MRT allows for defining the level of internal damage or wear of
the rope and wires for prediction of their possible service time.
2.2.5 Detailed guidelines for the application of selected methods and assessment of testing re-
sults shall be subject of a separate agreement with PRS.
2.3 Testing of rope terminations
2.3.1 Testing of rope termination made by metal or resin socketing shall be conducted accord-
ing to ISO 17558 std.

2.3.2 The rope shall be examined in the area where it passes out from the termination, as this
position is critical for the onset of fatigue damages (e.g. wire breaks) and corrosion. The terminal
fittings themselves shall be examined for signs of distortion or wear.
2.3.3 Terminations involving pressed or swaged ferrules shall be similarly examined, and the
ferrule shall be checked for cracks in the material and possible slippage between the ferrule and
the rope.
2.3.4 Detachable terminations (wedge sockets, grips), shall be examined for broken wires within
and under the termination and at its rim to ensure the tightness of wedges and screwed grips.
2.3.5 Eye splices made by hand shall be served only over the tail of the splice so as to protect the
hands from protruding wire, while at all times allowing the remainder of the splice to be inspected
for wire breaks. When broken wires become evident close to, or within, the termination, it may be
possible to shorten the rope and re-fix the terminal fittings. However, the remaining length of the
wire rope shall be sufficient to allow for the minimum required number of rope turns on the drum.

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2.3.6 In case of detection of any abnormalities in the wire rope detected, the rope is to be immedi-
ately removed from service and relevant details are to be included in the survey report created.

3 CRITERIA FOR THE ASSESSMENT OF WIRE ROPES WEAR

The assessment of wire rope wear is performed considering the following criteria:
– the number of broken wires in the rope,
– broken wires at rope end terminals,
– localized grouping of wire breaks,
– the rate of increase of the wire breaks,
– the fracture of strands,
– reduction of rope diameter resulting from core deterioration,
– decreased rope elasticity,
– external and internal abrasion,
– external and internal corrosion,
– rope deformation,
– damage due to heat radiation or electric arc,
– the rate of increase of rope permanent elongation.
3.1 Number of cracked wires in the rope
The level of rope wear may be defined on the basis of the number of broken wires in the external
layer (irrespective of the number of layers in the rope). The filling wires do not carry loads, there-
fore they shall not be considered. In steel core ropes, the core is regarded as internal strand and
it is not taken into account. In the case of 6- and 8- strand ropes, broken wires occur mainly at the
external surface, while in multi-strand ropes majority of breaks occurs internally, and are there-
fore non-visible fractures. This is considered in the wear criteria, given in Table 3.1.
Table 3.1
Group of work intensity of the crane
0 I – IV
No. of load
Kind of rope and length of examined portions L
bearing wires
Typical examples of
in outer ordinary lay langs lay ordinary lay langs lay
rope structure
strands 6d 30d 6d 30d 6d 30d 6d 30d
n
Number of visible broken wires on the length L
qualifying the rope for replacement
Up to 50 6 × 7 /6/1/ 2 4 1 2 4 8 2 4
6 × 19 /9/9/1/*
51 to 75 3 6 2 3 6 12 3 6
12 × 6/3 × 24
8 × 19 /9/9/1/*
6 × 19 /12/6/1/
6 × 19 /12/6+6F/1/
100 to 120 5 10 2 5 10 19 5 10
6 × 25F8 /12/12/1/*
34 × 7 /17 ext.
strands/
121 to 140 – 6 11 3 6 11 22 6 11
141 to 160 8 × 19 /12/6+6F/1/ 6 13 3 6 13 26 6 13
161 to 180 6 × 36 /14/7+7/7/1/* 7 14 4 7 14 29 7 14
181 to 200 – 8 16 4 8 16 32 8 16
201 to 220 6 ×41 /16/8+8/8/1/* 8 18 4 9 18 36 9 18

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221 to 240 6 × 37 /18/12/6/1/ 10 19 5 10 19 38 10 19

241 to 260 – 10 21 5 10 21 42 10 21
261 to 280 – 11 22 6 11 22 45 11 22
281 to 300 – 12 24 6 12 24 48 12 24
Above 300** – 0.04n 0.08n 0.02n 0.04n 0.08n 0.16n 0.04n 0.08n
d – rope diameter
* Rope structures in service, having outer wires in the strands of larger diameters than required in obligatory
standards.
** Calculated values shall be rounded off to a whole number.

3.2 Broken wires at rope termination

Broken wires at, or adjacent to, the termination, even if few in number, is an indication of high
stresses at this position, which may be caused by incorrect fitting of the termination. Investigation
of the cause of this deterioration shall be made and. After cutting the damaged length, the rope ter-
mination may be fixed again if sufficient length remains for further use.
3.3 Localized grouping of broken wires
Where broken wires are very close together, constituting local grouping of such breaks in a length
less than 6d or is concentrated in any one strand, it will be safer to discard the rope even when
the number of wire breaks is smaller than the maximum number given in Table 3.1.
3.4 The rate of increase of broken wires
In applications where the predominant cause of rope deterioration is fatigue, the commencement of
broken wires will begin after a certain period of usage, but the number of breaks will progressively
increase at ever-shortening intervals. In such cases, it is recommended that careful examination and
recording of the increase of broken wires should be undertaken with a view to establishing the rate
of increase of the breaks. It shall enable to approximate the date of the rope discard.
3.5 Fracture of strands
If a complete strand fracture occurs, the rope shall be discarded.
3.6 Reduction of the rope diameter due to core deterioration
If deterioration of a fibre core or fracture of a steel core (fracture of internal layers in a multi-strand
construction) cause reduction of rope diameter, the rope shall be discarded.
Small deterioration may not be so apparent from normal examination, particularly if the rope
stresses are well balanced throughout the individual strands. However, the condition may result
in a high loss of the rope strength, therefore it is recommended that any suggestion of such inter-
nal deterioration should be verified by internal examination. Where such deterioration is con-
firmed, the wire rope shall be discarded (see Attachment 2).
3.7 Decreased rope elasticity
Under certain circumstances usually associated with the working environment, a rope may sus-
tain a substantial decrease in elasticity and will be unsafe for further use.
Decreased elasticity is difficult to detect directly; usually it brings the following symptoms:
– reduction of rope diameter, not result of wires abrasion,
– elongation of the rope lay length,

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– lack of gap between individual wires and between strands, caused by the compression of the
component parts against each other (tendency to protrude wires or strands out of the rope),
– the appearance of fine, brown powder within the strand gussets,
– while no wire breaks may be visible, the wire rope will be noticeably stiffer to handle.
This condition can lead to abrupt failure under dynamic loading and is sufficient justification for
immediate discard.
3.8 External and internal wear
The wear is caused by two kinds of factors:
– abrasion of the crown wires of outer strands in the rope in result of rubbing contact, under
pressure, with the grooves in the pulleys and the drums. It is particularly evident on moving
ropes at points of pulley contact when the load is being accelerated or decelerated, and shows
itself as flat surfaces at places subject to chafing,
– internal wear and occurrence of notches is a result of rubbing between individual wires and
strands – in particular in sections subjected to bending around pulleys or drums.
The rope wear process may be accelerated in result of incorrect lubrication or lack of it and in
result of presence of dust or grit. The process reduces the strength of ropes by reducing the cross-
sectional area of the steel. When owing to external wear the actual rope diameter is reduced by
7% or more of the nominal diameter, the rope shall be discarded, even if no wire breaks are visible.
3.9 External and internal corrosion
Corrosion occurs particularly in the marine and industrial polluted atmospheres. It will not only
diminish the breaking strength of wire rope by reducing its metallic area but will also accelerate
fatigue by causing the irregular surface from which stress cracking will commence.
3.9.1 Guidance on identifying corrosion:
– the corrosion of outer wires is identified directly by visual examination,
– the internal corrosion (which frequently accompanies the external corrosion) is more difficult
to detect. It may be suspected based on ascertained changes of the rope diameter and loss of
gaps between the strands in the outer layer.
3.9.2 In positions where the rope bends around pulleys, a reduction in diameter usually occurs.
However, in stationary ropes (stays, preventer guys) it is not uncommon for an increase in diameter
to occur due to the build-up of rust under the outer layer of strands. Loss of gap between the strands
in the outer layer of the rope is frequently combined with wire breaks in the strand gussets.
3.9.3 If there is any suggestion of internal corrosion, the rope shall be subjected to internal ex-
amination, as indicated in Attachment 2, to be carried out by a competent person. Confirmation of
severe internal corrosion is justification for immediate rope discard.
3.9.4 Prevention corrosion present in wire ropes utilized in lifting appliances used in marine off-
shore and underwater works requires additional supervision. The relevant supervision procedure
shall include the application of appropriate inspection technique (such as VT and MRT) and shall be
adapted to the method of wire ropes service and be agreed with PRS prior to tests accepting the
rope for service in the lifting appliance. Based on the results of performed testing, supervision
principles and methods of further monitoring of the rope condition and periodical testing shall be
defined, to ensure safe operation of wire ropes used in exploitation of marine resources.

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3.10 Wire rope deformation

The wire rope deformation means visible distortion thereof from its normal formation. Stresses
have uneven distribution at the deformation position. Below are presented most often types of
wire rope deformations:
3.10.1 Waviness (Fig. 8 in Attachment 4 ). It is a deformation where the longitudinal axis of the
rope takes the shape of a helix. While not necessarily resulting in any loss of strength, such a defor-
mation, if severe, may transmit a pulsation resulting in irregular rope drive. After prolonged work-
ing, this will give rise to wear and wire breaks. The wire rope shall be discarded if (see Fig. 3.10.1):

d 1 ≥ 4/3 × d
where:
d1 – the diameter of a cylinder circumscribed on the deformed wire rope;
d – the nominal diameter of the wire rope
and the length of the rope under consideration does not exceed 25 × d

Fig. 3.10.1

3.10.2 Birdcage (basket deformation) (Fig. 9 in Attachment 4). The deformation occurs when
outer wires in strands separate from the core wires. The birdcaging occurs mostly in result of abrupt
loading of the rope from a slack condition. The deformation justifies immediate discard of the rope.
3.10.3 Strand extrusion (Fig. 10 in Attachment 4 ). The deformation is often associated with
basket deformation (birdcage), which causes uneven distribution of stresses in the rope. Such
wire rope shall be immediately discarded.

3.10.4 Wire extrusion (Figs. 11 and 12 in Attachment 4). In this condition, certain wires or
groups of wires rise up, when the wire rope rests in a pulley, in the form of loops – this usually
results from shock loading. If the deformation is severe, this is a justification for rope discard.
3.10.5 Local increase in the wire rope diameter (Figs. 13 and 14 in Attachment 4). The de-
formation is usually a result of distortion of fibre core (in some environments, the core can swell
up owing to the effect of moisture), and that causes uneven distribution of stresses in strands and
their incorrect orientation. If the deformation is severe, this is a justification for rope discard.
3.10.6 Local decrease of wire rope diameter (Fig. 17 in Attachment 4). The deformation is
frequently associated with fracture of a core. Positions close to rope terminations shall be carefully
examined for such deformations. If the deformation is severe, this is a justification for rope discard.
3.10.7 Flattened portions (Figs. 18 and 19 in Attachment 4). The deformation is a result of
a mechanical damage. If the deformation is severe, this is a justification for rope discard.

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3.10.8 Kinks of tightened loops (Figs. 15 and 16 in Attachment 4). The deformation is created
by a loop in the rope which has been tightened without allowing for a rotation about its axis. It
results in the change of the rope lay length and earlier wear of wires. More severe cases of rope
kinking result in loosing rope strength and are justification for immediate discard.
3.10.9 Rope bend (Fig. 20 in Attachment). It is an angular deformation of the rope caused by
external factors – justifies immediate discard of the wire rope.
3.11 Damage due to heat or electric arcing
Wire ropes, which have been subjected to heat radiation or electric arcing, externally recognized
by the colors produced, shall be discarded.
Literature:
− EN 12385-3:2020 Steel wire ropes – Safety – Part 3: Information for use and maintenance
− ISO 4309: 2010 – Cranes – Wire ropes – Care and maintenance, inspection and discard;
− ISO 17558:2006(en) - - Steel wire ropes — Socketing procedures — Molten metal and resin
socketing
− HSE OTH 341 – Wire rope offshore – review of wire rope endurance research affecting offshore
applications;
− HSE OTO 2000 064 – Wire rope Non-Destructive Testing – Survey of Instrument Manufactures;
− API Specification 2C – Offshore Pedestal-mounted Cranes – Machinery and Wire Rope Duty
Cycles

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ATTACHMENT 1

DIAGRAMMATIC ILLUSTRATION OF POSSIBLE DEFECTS TO BE CONSIDERED DURING

EXAMINATION

pulley 1. Termination of rope at drum and at permanent fixing.

2. Correctness of rope coiling on the drum.
3. Examination for wire breaks and rope wear.
4. Examination for corrosion.
5. Examination for deformations due to snatch loading.
6. Examination of portions which wind over drum, pulley
and pulley blocks.
7. Examination for changes of rope diameter and other de-
formations.

Defective rope coiling on the drum causes the rope flattening

and wires abrasion. Also the rope portions which are wound
drum around compensating pulley, or the one adjacent thereto,
shall be examined for wire breaks and corrosion.

pulley
block

load

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ATTACHMENT 2

INTERNAL EXAMINATION OF WIRE ROPE

1. General guidelines
Internal corrosion and fatigue cracking of wires are the prime reasons of the loss of rope strength.
External examination may not reveal the extent of internal deterioration, even to the point when
fracture is imminent. Internal examination shall therefore be carried out.
All types of stranded wire ropes can be opened up to permit assessment of their internal condi-
tion. Majority of ropes fitted on cranes can be examined internally, provided that they are at zero
tension.

2. Examination method
Opening ropes may be performed with use of clamps (see Fig. 1) with jaws suitable for the rope
diameter. The clamps are positioned on the rope at both ends of the examined portion to ensure
that the jaws do not slip and then forces shall be applied to the jaws in the opposite direction to
each other.

Fig. 1

The strands shall not be displaced excessively. When the wire rope opens, a screwdriver or other
small device may be used to remove grease or debris which could hinder observation of the inte-
rior of the rope.
During examination, the following shall be taken into account:
– the state of the internal lubrication,
– the degree of corrosion,
– indentation of wires caused by pressure or wear,
– presence of broken wires (these are not necessarily easily visible).

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After the examination, a service dressing provided by the rope manufacturer shall be inserted into
the opened part and rotation of the clamping jaws shall be effected with moderate force to ensure
correct replacement of the strands around the core. After removal of jaws, the outer surface of the
rope shall be greased.
In examining the rope portion adjacent to termination, it is sufficient to use a single jaw, since the
end anchorage system or a bar located through the end portion of the termination, will ensure the
necessary immobilization of the other end.

3. Portions which should be examined

Since it is impracticable to examine the interior of the wire rope over the whole of its length, suit-
able sections most susceptible to damage shall be selected:
– wire rope portions which wind onto the drum or pass over pulleys or rollers when the crane is
in a loaded condition;
– portions in which shock forces are arrested (caused by rapid lifting cargo without rope pre-
tension), i.e. adjacent to drum and jib lead pulleys;
– portions close to rope terminals, what is particularly important in the case of fixed ropes (stays,
pendants, etc.).

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ATTACHMENT 3

WIRE ROPE EXAMINATION RECORD

Data sheet for rope ........................................................................ Machine: .............................................................................................................
Application: ......................................................................................................
Construction: ...................................................................................................................................... Date fitted:
Direction of rope lay: RH/LH .............................................................................
Type of lay: ordinary/langs Date discarded: ...........................................
Nominal diameter: ........................................................................................................................... Minimum breaking load:
Tensile grade of wire: ..................................................................................................................... .............................................................................
Quality: galvanized/ungalvanized/stainless Working load: ..............................................
Type of core: steel/natural/synthetic textile
Preformation: ..................................................................................................................................... Diameter measured:
Length of rope: ................................................................................................................................... .............................................................................
Type of termination: ....................................................................................................................... Under a load of:
.............................................................................

Visible broken Abrasion of Overall

Corrosion Reduction of Damage and
wires outer wires Positions assessment
(Degree of de- rope diameter deformations
(number in (Degree of de- measured (Degree of de-
terioration)* (in %) (nature)
length of 6d) terioration)* terioration)*

Date: Signature:

Rope supplier: ......................................................................................................... Number of working hours: .............................................

.........................................................................................................................................
Reasons for discard: ..........................................................
Other observations: .......................................................................................................
.........................................................................................................................................

* In the columns „Degree of deterioration” describe it as „slight”, „medium”, „high”, „very high”, „discard”.

Notes:

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Guidance and useful hints for the wire rope examination:

1. Verify the source and manufacturer of all wire rope, and if purchased carefully observe the speci-
fications of the rope to ensure it matches the product that was purchased (i.e., construction (num-
ber of wires per strand and number of strands) and wire rope lay);
2. Visually examine wire rope terminations for abnormalities that may indicate improper installa-
tion. These ridges or abnormalities COULD be indicative of over-crimping, but any abnormalities
need to be verified based on the type of crimp and manufacturing die used in the crimping pro-
cess (i.e., some manufacturers’ dies have chambers for excess material that is then removed and
can leave lines that appear similar to ridges);
3. Compare all fitting dimensions against the approved documents and certificates comparing with
manufacturer’s specifications/tolerances for the completed fitting (i.e. verify whether the wire
rope length and diameter fall within fitting manufacturer specifications);
4. Verify that the wire rope termination type does not reduce the safe working load of the inspected
wire rope below the minimum safety factor for the relevant usage and service conditions;
5. If any abnormalities in the wire rope are detected, immediately remove the wire rope from ser-
vice and make an appropriate replacement

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ATTACHMENT 4

TYPICAL EXAMPLES OF DEFECTS THAY MAY OCCUR IN WIRE ROPE

For emphasis, some of figures show exaggerated deterioration and the ropes depicted should have
been discarded at an earlier stage.

Fig. 1.
Wire breaks and wire displacement over two adjacent strands in an ordinary lay rope –
justification for discard.

Fig. 2.
A large number of wire breaks, associated with heavy wear in an ordinary lay rope –
justification for immediate discard.

Fig. 3.
Wire breaks in one strand, associated with slight wear in a langs lay rope – further operation is acceptable if this con-
dition represents the worst condition (fractured wires shall be cut out so that the end is at the strand gusset; this pre-
vents further abrasion of the adjacent wires).

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Wear External corrosion

Slight flats on outer wires. Beginning of surface oxida-

tion.

Flats on individual wires

longer, affecting all crown Wires rough to touch.
wires in each strand. Consider- General surface oxidation.
able reduction in wire diame-
ter (other rope damages shall
be checked carefully).

Flats on individual wires al- Surface oxidation more ad-

most continuous, strands vanced.
slightly flattened and wires are
noticeably thin (serious dam-
ages could be justification for
rope discard, other damages
shall be checked and the fre-
quency of examination in-
creased).

Flats touch each other, wires Surface of wire greatly af-

becoming slack with an esti- fected by oxidation.
mated reduction in cross-sec-
tion of 40% (justification for
immediate discard).

Surface heavily pitted and

wires quite slack (justifica-
tion for immediate discard.

Fig. 4.
Examples of progression of wear and external corrosion in an ordinary lay rope

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Fig. 5.
Wire breaks in several strands, local to a compensating pulley (often hidden by this pulley) –
justification for immediate discard.

Fig. 6.
Wire breaks in two strands, local to a compensating pulley, caused by jamming of the pulley – justification for immedi-
ate discard.

Wires broken
in a multi-layer rope

Fig. 7.
Wire breaks in the internal layer of an ordinary lay rope, due to abrupt load – justification for immediate discard

Fig. 8.
Rope waviness (the longitudinal axis of the rope takes the shape of a helix).
If the deformation exceeds the value indicated in 3.10 – the rope shall be discarded.

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Fig. 9.
Basket deformation (bird cage) – deformation of a multi-strand construction –
justification for immediate discard.

Fig. 10.
Extrusion of a steel core, generally associated with a basket deformation (bird cage) –
justification for immediate discard.

Fig. 11.
One strand only affected by wire extrusion, examination over a length of rope shows that deformation is visible at reg-
ular intervals, normally of one lay length.

Fig. 12.
One strand only affected by wire extrusion (aggravation of the previous fault – Fig. 11),
typical of a hoist rope on a pilling machine – justification for immediate discard.

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Fig. 13
Local increase in rope diameter due to protrusion of the fibre core in a degraded condition between the outer strands.

Fig. 14
Severe kink or tightened loop – note the screwed-up lay causing the extrusion of the fibre core – justification for im-
mediate discard.

Fig. 15
A wire rope which has been kinked during installation but which has been placed in operation, and is in result subject
to localized wear and to wire slackness – justification for immediate discard.

Fig. 16
Local decrease in rope diameter, as the outer strands take place of the fibre core, which has disintegrated – justifica-
tion for immediate discard.

Polski Rejestr Statków 21

 Informative Publication 10/I
January 2022 Wire ropes for lifting appliances. Guidelines for condition assessment

Fig. 17
Flattened portion due to local crushing, creating imbalance in the strands and associated with broken wires – justifi-
cation for discard.

Fig. 18
Flattened portion of a rope caused by miscoiling on a drum.
Note how the lay length of the outer layer has increased due to local mechanical crushing and with imbalance of the
strands associated with broken wires – justification for discard.

Fig. 19
Example of severe bend – justification for discard.

22 Polski Rejestr Statków