This document provides safety guidance for using wire rope. It notes that wire rope should be treated like a machine and inspected regularly for defects as it can fail from misuse or wear over time. The document lists several defects to inspect for, such as broken wires, abrasion, kinking, and corrosion. It also recommends protecting wire rope from weather and lubricating it regularly to prevent failure and injuries like those described where a tow rope and hoist rope broke unexpectedly. Crews should be trained to properly inspect and care for wire ropes.

1. Construction Safety Talks
Wire Rope Some Things To Know Before You Give Your Talk.
Is A Tool Wire rope is so dependable that some people assume it will last
forever no matter how it is used.
No. 6
Tell your crew to think of wire rope as a machine; reliable when
used properly but able to be damaged by misuse and will
eventually wear out.
How This Talk
Applies To My Modern wire rope is made in a variety of constructions to
Crew: accommodate special requirements and applications. Are you
using the proper construction for you application?
Like with any machine, rope accidents can happen:
• a railroad car was being towed by a dozer. The tow rope
broke, snapping back striking a nearby observer.
• a hoist rope on a swinging scaffold failed causing two
masons to fall.
Both these accidents happened because the wire rope had
corroded.
Before you use a wire rope, inspect it for the following:
• broken wires (the number varies depending on use; look up
the manufacturer’s or OSHA’s recommendations),
• abrasion,
• kinking (kinked rope cannot lie flat),
• crushing,
• cracked fittings,
• loose seizing,
• signs of being exposed to high temperature,
• defects in the end connections,
• bird caging (caused by a sudden release of tension).
© 2003 Liberty Mutual Group – All Rights Reserved 1

2. Remind the crew to take care of wire rope cables and slings by protecting it from the
weather.
• Hang it up to protect it from physical damage and moisture
• Lubricating it regularly. This allows wires to move independently when turned
around a sheave.
• Avoid sharp bends, pinching, and crushing when rigging (use corner pads to
reduce abrasion).
Try This For Show And Tell!
Find a wire rope that needs to be thrown out. Ask the crew to take a look at it and tell
you why.
Questions You Can Use To Get Them Talking:
• Do you know of any defective wire rope on this site? What should you do if you
see any?
• How many of you have been injured by a wire rope? What happened?
• What does a bird cage look like?
Attended By:
The illustrations, instructions and principles contained in the material are general in scope and, to the best of our knowledge, current at
the time of publication. No attempt has been made to interpret any referenced codes, standards or regulations. Please refer to the
appropriate code, standard or regulation making authority for interpretation or clarification.
© 2003 Liberty Mutual Group – All Rights Reserved 2