The document discusses various types of wire rope deformations including bends, waves, helical deformations, and kinks. It defines each deformation, describes potential causes, and outlines industry standards for determining if a deformation requires removal from service. Key criteria include bend angles, wave diameters exceeding 10-33% of nominal rope diameter, and kinks which represent irreparable damage. Proper inspection and adherence to standards is emphasized for safety.

1. Crucial Calls When
Evaluating Wire Rope
John F. Groce, P.E.
Sr. Technical Service Engineer
WireCo WorldGroup

2. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
TOPICS
Bends
• Definitions – Angle versus curve
• ASME B30, ISO 4309
• Sources
Wave
• Definition
• ISO 4309, ASME B30, WRTB
• Sources
Helical Deformations
• Definition
• Sources
Kinks
• Definition
• Stages of a kink
• Sources
Current B30 replacement criteria (and OSHA)

3. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Definitions
• Bend – An angular shape or a curve causing a directional change from a straight line.
• ASME B30.5 5-2.4.4(d) Rope Maintenance – During installation, care should be exercised to
avoid dragging of the rope in dirt or around objects that will scrape, nick, crush, or induce
sharp bends in it.
• ISO 4309 3.5.11.9 Bends – Angular deformations of rope caused by external influence.
BENDS
Curve Angle

4. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
BENDS – CURVE

5. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
BENDS – CURVE
Bending in service – A 1” (25.4mm) wire rope
operates over a 30” (762mm) sheave. The
length of the rope side in contact with the
sheave will be approximately 3-1/8” (79.4mm)
shorter than the side away from the sheave.
This is accounted for by the movement and
adjustment of the wire rope’s individual
components as the rope is bent around the
sheave.
𝑳𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝒄𝒐𝒏𝒕𝒂𝒄𝒕 =
𝐶𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑐𝑒
2
(32π)
2
−
30π
2
= 𝟑. 𝟏𝟒 in
Length of
contact w/
sheave
Outside
length of
wire rope

6. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
BENDS – CURVE
Things to consider
• No written standard lists curves as a criteria for removal from service.
• Tensile tests have shown that wire rope samples with curves of varying degrees still met or
exceeded their associated MBFs.
• All wire ropes operating over sheaves or on-and-off a drum can potentially develop curves.
• The severity of a curve is directly related to load and the D/d ratio in play.
• Does the curve disappear under load?
• Are there other types of retirement criteria associated with the area?
Curve

7. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Definitions (cont.)
• WRTB, Wire Rope User’s Manual 4th Edition, Appendix D
Dogleg – Permanent bend or deformation, in a wire rope, caused by improper use or
handling.
BENDS – ANGLE
If no strand distortion is exhibited and the dogleg cannot be observed when
the rope is under tension, the rope can remain in service.

8. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
BENDS – ANGLE

9. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
BENDS – ANGLE

10. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
BENDS – ANGLE

11. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Definitions (cont.)
• The following is currently being considered for inclusion by ASME B30
Dogleg (severe) – A permanent, localized, irreparable angular bend or deformation in a wire
rope that restricts the natural adjustment of the rope's components during operation. It is
caused by improper use or handling and results in an indeterminate loss of strength in the
rope. This condition cannot be corrected and is cause for removal from service.
Dogleg (minor) – Bend or deformation exhibiting no associated strand distortion and cannot
be observed while the rope is under tension. Should be noted and the wire rope may remain
in service.
BENDS – ANGLE

12. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Things to consider
• The condition can accelerate wire rope degradation in area of dogleg.
• Was rope bent over sharp edge while under tension (perpendicular loading)?
• Any associated localized mechanical damage or strand distortion?
• Are rope components’ natural adjustment restricted?
• Does condition disappear under load?
• Severe doglegs are cause for removal from service.
BENDS – ANGLE
Angle

13. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Definition & Industry Standards for Rope Retirement
• Wave – Distortion in a wire rope’s structure that occurs when one or more outer strands
have moved from their original, natural position along the rope’s axis.
• ISO 4309 3.5.11.2 Waviness – A deformation in which the longitudinal axis of the wire rope
takes the shape of a helix under either a loaded or unloaded condition.
• ISO 4309 & WRTB’s Wire Rope User’s Manual – Both provide the same condition limits for
removal.
• ASME B30 – Currently does not address wave distortion.
WAVE

14. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Waviness – Rope, under any load condition, must be removed
from service if, in a straight portion that does not bend around
a sheave or drum, the following condition is met:
dw > 1.33d (33% increase over nominal)
Or, in a portion of rope that bends around a sheave or drum,
the following condition is met:
dw > 1.1d (10% increase over nominal)
Where :
d = nominal diameter of the rope
dw = diameter corresponding to the wave
d
dw
WAVE

15. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
d
dw
Currently under consideration by ASME B30
Any portion of a wire rope operating in a system.
dw > 1.1d (10% increase over nominal)
Where :
d = nominal diameter of the rope
dw = diameter corresponding to the wave
WAVE

16. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Possible sources to wave
• Manufacturing issues with the wire rope’s outer stands’ preforming.
• Tight sheaves (small grooving, rope over max. diameter specified).
• Buildup of twist (improper handling, poor installation practices, excessive fleet angles,
poor operating practices – use of an in-line swivel / load induced torque).
WAVE

17. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Things to consider
• Does the affected section operate over a sheave or drum?
• Has the diameter of the wave reached appropriate maximum?
• Check system grooving.
• Check rope diameter on unaffected sections on both sides of wave section.
• Check fleet angles (component alignment).
• Load induced torque occurring (load rotation, swivel usage)?
• Suggest reviewing installation procedures.
WAVE

18. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Definition
• Helix – A shape formed by a line that curves around and along a central line.
HELICAL DEFORMATION

19. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Definition
• Helix – A shape formed by a line that curves around and along a central line.
HELICAL DEFORMATION

20. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
HELICAL DEFORMATION

21. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
HELICAL DEFORMATION

22. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Things to consider
• Severity of the helix.
• Does it disappear under load?
• Any other removal criteria present?
• Do sheaves have proper D/d ratios?
• Are sheaves turning properly loaded and unloaded?
• Damage to guards, sheaves, shafts, or other components?
HELICAL DEFORMATION

23. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Definition
• Kink - A unique deformation of a wire rope caused by a loop of rope being pulled down
tight. It represents irreparable damage and an indeterminate loss of strength in the rope.
This condition cannot be corrected and is cause for removal from service.
Above definition currently being considered for inclusion by ASME B30
KINKS

24. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
2
3
1
Incorrect
KINKS – STAGES & SOURCES

25. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Permanent irreparable damage
KINKS – FINAL RESULT
Incorrect

26. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
KINKS – FINAL RESULT
Incorrect
Permanent irreparable damage

27. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
KINKS – FINAL RESULT
Permanent irreparable damage
Incorrect

28. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Possible sources
• Improper handling
• Buildup of twist (poor installation practices, excessive fleet angles, poor operating
practices, load induced torque – use of an in-line swivel or allowing the load to rotate).
KINKS

29. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Load induced torque
KINKS

30. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Load induced torque
KINKS

31. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Rotation Resistant
(Category 1)
Non-Rotation Resistant
(Standard)
SWIVELS – TWIST TEST VIDEOS

32. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
SWIVELS – EFFECTS ON STRENGTH

33. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
SWIVELS

34. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Wire rope is a consumable item
Inspection is necessary to determine remaining useful service life
All ropes should be visually inspected each day
A thorough inspection should be performed at least monthly
Inspection records should be kept
Inspections need to be performed while the rope is unloaded and relaxed
Inspections need to be performed by a competent person
Rope retirement criteria is based on local governing standards
INSPECTION – A MATTER OF SAFETY

35. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
B30.2 Overhead and Gantry Cranes
B30.3 Tower Cranes
B30.4 Portal and Pedestal Cranes
B30.5 Mobile and Locomotive Cranes
B30.6 Derricks
B30.7 Winches
B30.8 Floating Cranes and Floating Derricks
B30.13 Storage & Retrieval (SR) Machines and Associated Equipment
B30.16 Overhead Hoists (Underhung)
B30.24 Container Cranes
ASME B30 – Safety Standards for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and
Slings
INSPECTION – A MATTER OF SAFETY

36. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
* Or 1 Valley Break
ASME
Standard Title
# of Broken Wires Away from End
Connections *
At End Connections
In one rope lay In one strand in
one rope lay
B30.2
Overhead & Gantry
Cranes
All running ropes 12 4 Not Stated
B30.3 Tower Cranes
Standard 12 4
> 2
Rotation Resistant 2 over 6 Dia 4 over 30 Dia
B30.4
Portal & Pedestal
Cranes
Standard 6 3
> 2
Rotation Resistant 4 2
B30.5
Mobile & Locomotive
Cranes
Standard 6 3
Not stated
(> 2 recommended)Rotation Resistant 2 over 6 Dia 4 over 30 Dia
B30.24 Container Cranes Standard 6 3 >2
INSPECTION – A MATTER OF SAFETY
ASME B30 – Safety Standards for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and
Slings

37. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Broken wires – Running wire ropes
• 6, 3, or 1 valley – Non-rotation-resistant (standard) wire ropes
• 2 over 6 dia or 4 over 30 dia or 1 valley – Rotation-resistant wire ropes
Core protruding between outer strands
Kinking, crushing, birdcaging, or any other damage resulting in distortion of the rope structure
Apparent damage from any heat source
Reduction from nominal of more than 5%
Broken wires – Standing wire ropes
• 3 in one lay or 2 or more at end connections
Inspections (5-2.4.2)
• Frequent – Daily visual, no records required, rope reasonably expected to be used
• Periodic – At least annually, frequency determined by qualified person, records required,
entire length of rope
INSPECTION – A MATTER OF SAFETY
ASME B30.5 – Mobile and Locomotivie Cranes

38. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
INSPECTION – A MATTER OF SAFETY

39. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
Re-lubing is an essential part of
maintenance
LUBRICATION MAINTENANCE

40. All contents © 2015 WireCo WorldGroup Inc. All rights reserved.
THANK YOU. QUESTIONS?