inspection of wire ropes - wire and fibre rope · pdf fileintroduction the most important...

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INTRODUCTION The most important aspect of operating a rope safely is regular proper inspection. ASME crane safety standards such as B30.2 and B30.5 provide detailed inspection procedures and retirement criteria. Both standards specify that all running ropes in service should be visually inspected once each working day and shall consist of observation of all rope that can reasonably be expected to be in use during operations on that day. The inspection must be more than just a quick look. It needs to be done carefully and in enough light to find damage or broken wires that may require the rope to be taken out of service. It must also be remembered that a dirty or greasy rope is almost impossible to inspect properly, as dirt and grease may hide problem areas. The individual making the inspection should be familiar with the machine, the wire rope, and that particular application. The B30 standards provide information on both a frequent inspection to be done daily and a much more detailed periodic inspection that is done on a weekly or monthly basis. FREQUENT INSPECTION As stated previously, all running ropes in service should be visually inspected once each working day and shall consist of observation of all rope that can reasonably be expected to be in use during operations on that day. The inspector should know where and how rope on the particular application wears out so that the daily inspection can be focused on the known wear areas. Special care should always be taken when inspecting common repetitive wear sections such as: Flange step up, cross over points and repetitive pick up on the drum; areas of the rope operating through a reverse bend in the reeving system, equalizer sheaves, and end connections. The inspector should be concerned with discovering gross damage that may be an immediate hazard. Specific types of damage include the following: Distortion to the uniform structure of the rope; broken wires; corrosion, gross damage to or deterioration of end connections, evidence of heat/electrical/lightning damage, and localized change in lubrication condition. When damage is discovered, a qualified person must evaluate affected sections as detailed in the rope replacement section below to determine if the rope needs to be removed from service. The B30 standards do not require frequent inspections to be documented, but it is a good idea to keep a frequent inspection log on the crane, simply noting time, date and identity of the inspector. PERIODIC INSPECTION The inspection frequency needs to be based on factors such as expected rope life as determined by experience on the particular installation or similar installations, severity of environment, percentage of capacity lifts, frequency rates of operation, and exposure to shock loads. Inspections need not be at equal calendar intervals and should be more frequent as the rope approaches the end of its useful life. There are many duty cycle rope applications where the service life is less than a month, or sometimes even a week in severe service conditions, so a periodic level of inspection may have to be performed daily. The periodic inspection must cover the surface of the entire rope length and no attempt should be made to open the rope. In addition to common repetitive wear sections checked during the frequent inspection, additional sections prone to rapid deterioration such as the following need special attention. (1) Locations where rope vibrations are damped, such as the following: sections in contact with equalizer sheaves, or other sheaves where rope travel is limited; sections of the rope at or near end connections where corroded or broken wires may protrude; bridle reeving in the boom hoist ropes; repetitive pickup points and crossover and change of layer points at flanges on drums; fleeting or deflector sheaves. In addition to the specific types of damage listed in the frequent inspection section, these additional items need to be addressed: Measuring the rope diameter in numerous locations to assess uniform loss of diameter along the entire length of rope; close visual observation of the entire length to identify; lengthening of lay in localized areas; diameter reduction in localized areas; distortion of rope structure (kinking, birdcaging, crushing); steel core protrusion between the outer strands; internal corrosion; wear of outside wires; more detailed inspection of end connections for broken wires and corrosion; severely corroded, cracked, bent, worn or improperly applied end connections; waviness (corkscrew effect) of rope; high or low strand. To establish data as a basis for judging the proper time for replacement, a dated report of rope condition at each periodic inspection must be kept on file. This report shall cover points of deterioration listed above. If the rope is replaced, only the fact that the rope was replaced need be recorded. Certain types of ropes and applications require special attention and require reduced time intervals between periodic inspections: •Rotation Resistant ropes have a unique construction and are susceptible to damage and increased deterioration when working under difficult conditions such as duty cycle operation. •Boom hoist ropes because of the importance of their function and because their location may make inspection difficult. ROPE REPLACEMENT There are no precise rules to determine the exact time for the replacement of the rope since many variable factors are involved. Once a rope reaches any one of the removal criteria, it must be replaced immediately unless allowed to operate to the end of the work shift by the judgment of a qualified person. If the rope was not removed immediately, it shall be replaced before the end of the next work shift. Specific inspection attributes and removal criteria are: (1) Broken wires: (a) For ropes operating on equipment covered by B30.5: In running ropes, 6 randomly distributed wire breaks per rope lay or 3 wire breaks per strand per rope lay. A rope lay is the distance that it takes one outer strand to make one complete revolution around the rope. A 6-strand rope will typically have a rope lay of 6.4 times the rope diameter (i.e. a 1/2” 6x25FW EIP IWRC RRL rope will have rope lay of 3.2”) (b) For ropes operating on equipment covered by B30.2, in running ropes is 12 randomly distributed wire breaks per rope lay or four wire breaks per strand (c) For all categories of Rotation Resistant ropes, the retirement criteria is 2 wire breaks in 6 rope diameters or 4 wire breaks on 30 rope diameters (i.e. 6 rope diameters in a 1” rope is 6”) (d) One broken outer wire at the contact point with the core which has worked its way out of the rope structure and protrudes, loops out or is slightly raised from the body of the rope Note: Broken wire removal criteria cited in this volume apply to wire rope operating on steel sheaves and drums and wire rope operating on multilayer drums regardless of sheave material. Due to the difficulty in detecting wire breaks when polymer are utilized with single layer drums, the user should contact the sheave manufacturer for broken wire removal criteria. Reductions from nominal diameter greater than 5% (Minimum Value = Nominal Diameter x .95) Distortion of rope structure: (a) Damage resulting in distortion of the rope structure (e.g., kinking, birdcaging, crushing) (b) Steel core protrusion between the outer strands (c) Localized change in lay length (d) Changes in original geometry due to crushing forces where the diameter across the distorted section is 5/6 of the nominal diameter. (4) Waviness (corkscrew effect) in the rope that causes overall diameter to increase to a value greater than 110% of nominal rope diameter. (5) A high or low strand that is higher or lower than ½ of the strand diameter above or below the surface of the rope. (6) Any apparent damage from a heat source including, but not limited to welding, power line strikes, or lightning. (7) Widespread or localized external corrosion as evidenced by pitting, and obvious signs of internal corrosion such as magnetic debris coming from valleys. (8) Severely corroded, cracked, bent, worn, grossly damaged, or improperly installed end connections Note: Consult the latest edition of the ASME B30 Volume that applies to your crane as removal criteria may be updated over time based on the latest knowledge and information. All rope that has been idle for a month or more due to shut down or storage of a crane should be given a detailed inspection according to the requirements of the periodic inspection provided by the B30 standards. ROPE SERVICE LIFE A long-range inspection program should be established and should include records on the examination of ropes removed from service so that a relationship can be established between visual observation and actual condition of the internal structure. There are a wide variety of wire rope constructions available to be used on cranes. It is important that the correct rope be used for each specific application. Because wire rope wears in service, the method by which the rope wears is an important factor in determining the most suitable rope. Replacement rope must have a rated strength at least equal to the original rope supplied or recommended for the machine. Any change from the original specification for the rope must be specified by the wire rope manufacturer, crane manufacturer, or qualified person. When there is a question, consult with Bridon American about the rope construction most appropriate for the application. HIGH PERFORMANCE WIRE ROPES ENDURANCE DYFORM 34LR/XL/MAX • Best combination of strength, rotation resistance, crush resistance and bendi fatigue in the rotation resistant product range • Strongest of all ropes in the rotation resistant product range confirmed by Bridon’s “Powerchecked” testing of a sample from each production length. • Greatest resistance to rotation of all ropes in the rotation resistant product range - confirmed by Bridon’s unique “Twistchecked” type testing program. • Superior bending fatigue life when compared with conventional rotation resistant ropes - confirmed by laboratory testing and extensive field experience • Excellent resistance to crushing and abrasion resulting from the overall compactness and robustness of the rope and the Dyform strands -recommended when multi-layer spooling is involved • Reduced elongation results from increased steel content and the Dyform process • Dimensional stability • Optional plastic coating (PI) of IWRC to further extend fatigue life, improve structural stability and resistance to corrosion ENDURANCE DYFORM 28 HML/ MAX • Provides up to 20% greater fatigue performance when compared with conventional multistrand ropes • Strongest of all ropes in the rotation resistant product range confirmed by Bridon’s “Powerchecked” testing of a sample from each production length • Greatest resistance to rotation of all ropes in the rotation resistant product range - confirmed by Bridon’s unique “Twistchecked” type testing program • Superior bending fatigue life when compared with conventional rotation resistant ropes - confirmed by laboratory testing and extensive field experience • Excellent resistance to crushing and abrasion resulting from the overall compactness and robustness of the rope and the Dyform strands -recommended when multi-layer spooling is involved • Reduced elongation results from increased steel content and the Dyform process • Dimensional stability ENDURANCE DYFORM 18/PI • High strength rotation resistant rope incorporating Dyform strands- confirmed by Bridon’s “Powercheck” testing of a sample from each production length. • Good resistance to rotation - confirmed by Bridon’s unique “Twistchecked” type testing program • Superior bending fatigue life when compared with conventional multistrand ropes - confirmed by laboratory testing and extensive field experience. • Excellent resistance to crushing and abrasion resulting from the overall compactness and robustness of the rope and the Dyform strands are recommended when multi-layer spooling is involved • Optional plastic coating (PI) of IWRC to further extend fatigue life, improved structural stability and resistance to corrosion ENDURANCE DYFORM 6/PI • Strongest of all ropes in the six strand product range-confirmed by Bridon’s “Powerchecked” testing of a sample from each production length • Superior bending fatigue life when compared with conventional six strand ropes - confirmed by laboratory testing and extensive field experience • Excellent resistance to crushing and abrasion resulting from the overall compactness and robustness of the rope and the Dyform strands - recommended when multi-layer spooling is involved • Reduced elongation results from increased steel content and the Dyform process • Optional plastic coating (PI) of IWRC to further extend fatigue life, improved structural stability and resistance to corrosion ENDURANCE DYFORM 8/PI/MAX • High breaking force - confirmed by Bridon’s “Powerchecked” testing of a sample from each production length • Superior bending fatigue life when compared with conventional eight strand ropes - confirmed by laboratory testing and extensive field experience • Highest strength boom hoist rope offered by Bridon • Excellent resistance to crushing and abrasion resulting from the overall compactness and robustness of the rope and the Dyform strands - recommended when multi-layer spooling is involved • Reduced elongation results from increased steel content and the Dyform process • Optional plastic coating (PI) of IWRC to further extend fatigue life, improved structural stability and resistance to corrosion CONSTRUCTEX® • Nine strand rope comprised of three different strand constructions. Each outside strand manufactured with a soft plastic center • High strength - confirmed by Bridon’s “Powerchecked” testing of a sample • Excellent resistance to crushing and wear resulting from the overall compactness and robustness of the rope • Flexible construction with good fatigue life in most applications STANDARD WIRE ROPES 6X19 CLASSIFICATION • High quality six strand rope • High strength - confirmed by Bridon’s “Powercheck” testing of a sample (where noted in table) • Excellent resistance to wear • Fully lubricated • Steel core and fiber core 6X36 CLASSIFICATION • High quality six strand rope • High strength - confirmed by Bridon’s “Powercheck” testing of a sample (where noted in table) • Consistent bending fatigue performance • Fully lubricated • Steel core and fiber core 05/2016 Bridon American Corporation 280 New Commerce Blvd. Wilkes-Barre, PA. 18706 PHONE: 1-800-521-5555 FAX: 1-800-233-8362 EMAIL: [email protected] www.bridonamerican.com DISCLAIMER: All statements, technical information, and recommendations contained herein are believed reliable, but no guarantee is given as to their accuracy and/ or completeness. This publication and the products described herein may be changed or updated without notice. This publication is made available on the basis that all liability whatsoever for any loss or damage arising, directly or indirectly, out of or in connection with your use of this publication, is excluded to the fullest extent permitted by law. The user must determine the suitability of the product for his particular purpose either alone or in combination with other products and shall assume all risk and liability in connection therewith. While every attempt has been made to ensure accuracy in the content of the training and tables, the content in this publication does not form part of any contract. This document is published by Bridon American. Use of this publication shall be governed in accordance with the laws of the United States and Pennsylvania courts shall have exclusive jurisdiction over any dispute concerning your use of this publication. INTELLECTUAL PROPERTY: All rights reserved. No parts of this publication may be reproduced or transmitted in any form or by any means, including photocopying and recording, without the written permission of the copyright holder, application for which should be addressed to Bridon American. Such written permission must also be obtained before any part of this publication is stored in a retrieval system of any nature. All trademarks used in this publication belong to Bridon or the registered proprietors of such marks. All rights relating to such trademarks, copyright, and any other intellectual property rights are reserved for Bridon or the person/organization contributing the relevant materials. Dyform is a registered trademark of Bridon American Corporation. Item number, Edition 05/2016 © 2016, Bridon American. Integrity in Every Strand Quick Reference Guide: Crane Ropes Inspection of Wire Ropes

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Page 1: Inspection of Wire Ropes - Wire and Fibre Rope · PDF fileINTRODUCTION The most important aspect of operating a rope safely is regular proper inspection. ASME crane safety standards

INTRODUCTION

The most important aspect of operating a rope safely is regular proper inspection. ASME crane safety standards such as B30.2 and B30.5 provide detailed inspection procedures and retirement criteria. Both standards specify that all running ropes in service should be visually inspected once each working day and shall consist of observation of all rope that can reasonably be expected to be in use during operations on that day. The inspection must be more than just a quick look. It needs to be done carefully and in enough light to find damage or broken wires that may require the rope to be taken out of service. It must also be remembered that a dirty or greasy rope is almost impossible to inspect properly, as dirt and grease may hide problem areas. The individual making the inspection should be familiar with the machine, the wire rope, and that particular application. The B30 standards provide information on both a frequent inspection to be done daily and a much more detailed periodic inspection that is done on a weekly or monthly basis.

FREQUENT INSPECTION

As stated previously, all running ropes in service should be visually inspected once each working day and shall consist of observation of all rope that can reasonably be expected to be in use during operations on that day. The inspector should know where and how rope on the particular application wears out so that the daily inspection can be focused on the known wear areas. Special care should always be taken when inspecting common repetitive wear sections such as:

Flange step up, cross over points and repetitive pick up on the drum; areas of the rope operating through a reverse bend in the reeving system, equalizer sheaves, and end connections.

The inspector should be concerned with discovering gross damage that may be an immediate hazard. Specific types of damage include the following:

Distortion to the uniform structure of the rope; broken wires; corrosion, gross damage to or deterioration of end connections, evidence of heat/electrical/lightning damage, and localized change in lubrication condition.

When damage is discovered, a qualified person must evaluate affected sections as detailed in the rope replacement section below to determine if the rope needs to be removed from service. The B30 standards do not require frequent inspections to be documented, but it is a good idea to keep a frequent inspection log on the crane, simply noting time, date and identity of the inspector.

PERIODIC INSPECTION

The inspection frequency needs to be based on factors such as expected rope life as determined by experience on the particular installation or similar installations, severity of environment, percentage of capacity lifts, frequency rates of operation, and exposure to shock loads. Inspections need not be at equal calendar intervals and should be more frequent as the rope approaches the end of its useful life. There are many duty cycle rope applications where the service life is less than a month, or sometimes even a week in severe service conditions, so a periodic level of inspection may have to be performed daily.

The periodic inspection must cover the surface of the entire rope length and no attempt should be made to open the rope. In addition to common repetitive wear sections checked during the frequent inspection, additional sections prone to rapid deterioration such as the following need special attention.

(1) Locations where rope vibrations are damped, such as the following: sections in contact with equalizer sheaves, or other sheaves where rope travel is limited; sections of the rope at or near end connections where corroded or broken wires may protrude; bridle reeving in the boom hoist ropes; repetitive pickup points and crossover and change of layer points at flanges on drums; fleeting or deflector sheaves.

In addition to the specific types of damage listed in the frequent inspection section, these additional items need to be addressed: Measuring the rope diameter in numerous locations to assess uniform loss of diameter along the entire length of rope; close visual observation of the entire length to identify; lengthening of lay in localized areas; diameter reduction in localized areas; distortion of rope structure (kinking, birdcaging, crushing); steel core protrusion between the outer strands; internal corrosion; wear of outside wires; more detailed inspection of end connections for broken wires and corrosion; severely corroded, cracked, bent, worn or improperly applied end connections; waviness (corkscrew effect) of rope; high or low strand.

To establish data as a basis for judging the proper time for replacement, a dated report of rope condition at each periodic inspection must be kept on file. This report shall cover points of deterioration listed above. If the rope is replaced, only the fact that the rope was replaced need be recorded.

Certain types of ropes and applications require special attention and require reduced time intervals between periodic inspections:

• Rotation Resistant ropes have a unique construction and are susceptible to damage and increased deterioration when working under difficult conditions such as duty cycle operation.

• Boom hoist ropes because of the importance of their function and because their location may make inspection difficult.

ROPE REPLACEMENT

There are no precise rules to determine the exact time for the replacement of the rope since many variable factors are involved. Once a rope reaches any one of the removal criteria, it must be replaced immediately unless allowed to operate to the end of the work shift by the judgment of a qualified person. If the rope was not removed immediately, it shall be replaced before the end of the next work shift. Specific inspection attributes and removal criteria are:

(1) Broken wires: (a) For ropes operating on equipment covered by B30.5: In running ropes, 6 randomly distributed wire breaks per rope lay or 3 wire breaks per strand per rope lay. A rope lay is the distance that it takes one outer strand to make one complete revolution around the rope. A 6-strand rope will typically have a rope lay of 6.4 times the rope diameter (i.e. a 1/2” 6x25FW EIP IWRC RRL rope will have rope lay of 3.2”) (b) For ropes operating on equipment covered by B30.2, in running ropes is 12 randomly distributed wire breaks per rope lay or four wire breaks per strand (c) For all categories

of Rotation Resistant ropes, the retirement criteria is 2 wire breaks in 6 rope diameters or 4 wire breaks on 30 rope diameters (i.e. 6 rope diameters in a 1” rope is 6”) (d) One broken outer wire at the contact point with the core which has worked its way out of the rope structure and protrudes, loops out or is slightly raised from the body of the rope

Note: Broken wire removal criteria cited in this volume apply to wire rope operating on steel sheaves and drums and wire rope operating on multilayer drums regardless of sheave material. Due to the difficulty in detecting wire breaks when polymer are utilized with single layer drums, the user should contact the sheave manufacturer for broken wire removal criteria.

Reductions from nominal diameter greater than 5% (Minimum Value = Nominal Diameter x .95)

Distortion of rope structure: (a) Damage resulting in distortion of the rope structure (e.g., kinking, birdcaging, crushing) (b) Steel core protrusion between the outer strands (c) Localized change in lay length (d) Changes in original geometry due to crushing forces where the diameter across the distorted section is 5/6 of the nominal diameter. (4) Waviness (corkscrew effect) in the rope that causes overall diameter to increase to a value greater than 110% of nominal rope diameter.

(5) A high or low strand that is higher or lower than ½ of the strand diameter above or below the surface of the rope. (6) Any apparent damage from a heat source including, but not limited to welding, power line strikes, or lightning.(7) Widespread or localized external corrosion as evidenced by pitting, and obvious signs of internal corrosion such as magnetic debris coming from valleys. (8) Severely corroded, cracked, bent, worn, grossly damaged, or improperly installed end connectionsNote: Consult the latest edition of the ASME B30 Volume that applies to your crane as removal criteria may be updated over time based on the latest knowledge and information. All rope that has been idle for a month or more due to shut down or storage of a crane should be given a detailed inspection according to the requirements of the periodic inspection provided by the B30 standards.ROPE SERVICE LIFE

A long-range inspection program should be established and should include records on the examination of ropes removed from service so that a relationship can be established between visual observation and actual condition of the internal structure. There are a wide variety of wire rope constructions available to be used on cranes. It is important that the correct rope be used for each specific application. Because wire rope wears in service, the method by which the rope wears is an important factor in determining the most suitable rope. Replacement rope must have a rated strength at least equal to the original rope supplied or recommended for the machine. Any change from the original specification for the rope must be specified by the wire rope manufacturer, crane manufacturer, or qualified person. When there is a question, consult with Bridon American about the rope construction most appropriate for the application.

HIGH PERFORMANCE WIRE ROPESENDURANCE DYFORM 34LR/XL/MAX • Best combination of strength, rotation resistance, crush resistance and bendi fatigue in the rotation resistant product range • Strongest of all ropes in the rotation resistant product range confirmed by Bridon’s “Powerchecked” testing of a sample from each production length. • Greatest resistance to rotation of all ropes in the rotation resistant product range - confirmed by Bridon’s unique “Twistchecked” type testing program. • Superior bending fatigue life when compared with conventional rotation resistant ropes - confirmed by laboratory testing and extensive field experience • Excellent resistance to crushing and abrasion resulting from the overall compactness and robustness of the rope and the Dyform strands -recommended when multi-layer spooling is involved • Reduced elongation results from increased steel content and the Dyform process • Dimensional stability • Optional plastic coating (PI) of IWRC to further extend fatigue life, improve structural stability and resistance to corrosion

ENDURANCE DYFORM 28 HML/ MAX • Provides up to 20% greater fatigue performance when compared with conventional multistrand ropes • Strongest of all ropes in the rotation resistant product range confirmed by Bridon’s “Powerchecked” testing of a sample from each production length • Greatest resistance to rotation of all ropes in the rotation resistant product range - confirmed by Bridon’s unique “Twistchecked” type testing program • Superior bending fatigue life when compared with conventional rotation resistant ropes - confirmed by laboratory testing and extensive field experience • Excellent resistance to crushing and abrasion resulting from the overall compactness and robustness of the rope and the Dyform strands -recommended when multi-layer spooling is involved • Reduced elongation results from increased steel content and the Dyform process • Dimensional stability

ENDURANCE DYFORM 18/PI • High strength rotation resistant rope incorporating Dyform strands- confirmed by Bridon’s “Powercheck” testing of a sample from each production length. • Good resistance to rotation - confirmed by Bridon’s unique “Twistchecked” type testing program • Superior bending fatigue life when compared with conventional multistrand ropes - confirmed by laboratory testing and extensive field experience. • Excellent resistance to crushing and abrasion resulting from the overall compactness and robustness of the rope and the Dyform strands are recommended when multi-layer spooling is involved • Optional plastic coating (PI) of IWRC to further extend fatigue life, improved structural stability and resistance to corrosion

ENDURANCE DYFORM 6/PI • Strongest of all ropes in the six strand product range-confirmed by Bridon’s “Powerchecked” testing of a sample from each production length • Superior bending fatigue life when compared with conventional six strand ropes - confirmed by laboratory testing and extensive field experience • Excellent resistance to crushing and abrasion resulting from the overall compactness and robustness of the rope and the Dyform strands - recommended when multi-layer spooling is involved • Reduced elongation results from increased steel content and the Dyform process • Optional plastic coating (PI) of IWRC to further extend fatigue life, improved structural stability and resistance to corrosion

ENDURANCE DYFORM 8/PI/MAX • High breaking force - confirmed by Bridon’s “Powerchecked” testing of a sample from each production length • Superior bending fatigue life when compared with conventional eight strand ropes - confirmed by laboratory testing and extensive field experience • Highest strength boom hoist rope offered by Bridon • Excellent resistance to crushing and abrasion resulting from the overall compactness and robustness of the rope and the Dyform strands - recommended when multi-layer spooling is involved • Reduced elongation results from increased steel content and the Dyform process • Optional plastic coating (PI) of IWRC to further extend fatigue life, improved structural stability and resistance to corrosion

CONSTRUCTEX® • Nine strand rope comprised of three different strand constructions. Each outside strand manufactured with a soft plastic center • High strength - confirmed by Bridon’s “Powerchecked” testing of a sample • Excellent resistance to crushing and wear resulting from the overall compactness and robustness of the rope • Flexible construction with good fatigue life in most applications

STANDARD WIRE ROPES6X19 CLASSIFICATION • High quality six strand rope • High strength - confirmed by Bridon’s “Powercheck” testing of a sample (where noted in table) • Excellent resistance to wear • Fully lubricated • Steel core and fiber core

6X36 CLASSIFICATION • High quality six strand rope • High strength - confirmed by Bridon’s “Powercheck” testing of a sample (where noted in table) • Consistent bending fatigue performance • Fully lubricated • Steel core and fiber core

05/2016

Bridon American Corporation 280 New Commerce Blvd. Wilkes-Barre, PA. 18706PHONE: 1-800-521-5555 FAX: 1-800-233-8362 EMAIL: [email protected] www.bridonamerican.com

DISCLAIMER: All statements, technical information, and recommendations contained herein are believed reliable, but no guarantee is given as to their accuracy and/ or completeness. This publication and the products described herein may be changed or updated without notice. This publication is made available on the basis that all liability whatsoever for any loss or damage arising, directly or indirectly, out of or in connection with your use of this publication, is excluded to the fullest extent permitted by law. The user must determine the suitability of the product for his particular purpose either alone or in combination with other products and shall assume all risk and liability in connection therewith. While every attempt has been made to ensure accuracy in the content of the training and tables, the content in this publication does not form part of any contract. This document is published by Bridon American. Use of this publication shall be governed in accordance with the laws of the United States and Pennsylvania courts shall have exclusive jurisdiction over any dispute concerning your use of this publication.INTELLECTUAL PROPERTY: All rights reserved. No parts of this publication may be reproduced or transmitted in any form or by any means, including photocopying and recording, without the written permission of the copyright holder, application for which should be addressed to Bridon American. Such written permission must also be obtained before any part of this publication is stored in a retrieval system of any nature. All trademarks used in this publication belong to Bridon or the registered proprietors of such marks. All rights relating to such trademarks, copyright, and any other intellectual property rights are reserved for Bridon or the person/organization contributing the relevant materials.

Dyform is a registered trademark of Bridon American Corporation.Item number, Edition 05/2016 © 2016, Bridon American.

Integrity in Every Strand

Quick Reference Guide: Crane Ropes

Inspection of Wire Ropes

Page 2: Inspection of Wire Ropes - Wire and Fibre Rope · PDF fileINTRODUCTION The most important aspect of operating a rope safely is regular proper inspection. ASME crane safety standards

DiameterNominal Rope Length Mass

Min Breaking ForceEIP/1960 EEIP/2160

mm in kg/m lbs/ft kN Tons (metric)

Tons (short) kN Tons

(metric)Tons

(short) 3/8 0.417 0.280 78.2 7.97 8.79 81.5 8.31 9.16

10 0.458 0.308 86.2 8.79 9.69 89.9 9.17 10.111 7/16 0.555 0.373 106 10.8 11.9 109 11.1 12.312 0.661 0.444 124 12.6 13.9 129 13.2 14.5

1/2 0.740 0.497 136 13.9 15.3 145 14.8 16.313 0.775 0.521 142 14.5 16.0 152 15.5 17.114 0.900 0.605 165 16.8 18.5 176 17.9 19.8

9/16 0.938 0.630 172 17.5 19.3 183 18.7 20.616 5/8 1.16 0.777 212 21.6 23.8 230 23.5 25.918 1.48 1.00 268 27.3 30.1 291 29.7 32.719 3/4 1.65 1.11 299 30.5 33.6 324 33.0 36.420 1.82 1.22 331 33.8 37.2 359 36.6 40.422 2.20 1.48 401 40.9 45.1 435 44.4 48.9

7/8 2.27 1.52 401 40.9 45.1 435 44.4 48.924 2.63 1.77 477 48.6 53.6 518 52.8 58.2

1 2.95 1.98 534 54.5 60.0 580 59.1 65.226 3.09 2.07 560 57.1 62.9 607 61.9 68.228 3.57 2.40 649 66.2 72.9 704 71.8 79.1

1 1/8 3.75 2.52 676 68.9 76.0 734 74.8 82.530 4.11 2.76 745 76.0 83.7 809 82.5 90.932 1 1/4 4.61 3.10 848 86.5 95.3 920 93.8 10334 5.27 3.54 957 97.6 108 1040 106 117

1 3/8 5.56 3.73 1010 103 114 1100 112 12436 5.91 3.97 1070 109 120 1160 118 13038 1 1/2 6.59 4.42 1200 122 135 1300 133 146

Endurance Dyform® 6/6PI

Standard Hoist Wire Ropes High Performance ® Main/Auxiliary Hoist Wire Ropes

Blue Strand 6x19 and 6x36

DiameterNominal Rope Length Mass

Min Breaking Force

EIP/1960 EEIP/2160

mm in kg/m lbs/ft kNTons

(metric)Tons

(short)kN

Tons

(metric)

Tons

(short)1/4 0.161 0.108 30.2 3.08 3.39

7 0.196 0.132 34.2 3.49 3.845/16 0.252 0.169 46.9 4.78 5.27

8 0.256 0.172 44.7 4.56 5.029 0.324 0.218 56.5 5.76 6.35

3/8 0.363 0.244 67.2 6.85 7.5510 0.400 0.269 69.8 7.12 7.85 76.9 7.84 8.6411 7/16 0.494 0.332 90.7 9.25 10.2 100 10.2 11.212 0.576 0.387 100 10.2 11.2 111 11.3 12.5

1/2 0.645 0.434 118 12.0 13.3 130 13.3 14.613 0.676 0.454 118 12.0 13.3 130 13.3 14.614 0.784 0.527 137 14.0 15.4 151 15.4 17.0

9/16 0.817 0.549 149 15.2 16.7 165 16.8 18.516 5/8 1.02 0.688 183 18.7 20.6 202 20.6 22.718 1.30 0.871 226 23.0 25.4 249 25.4 28.019 3/4 1.45 0.975 262 26.7 29.4 288 29.4 32.420 1.60 1.08 279 28.5 31.4 308 31.4 34.622 1.98 1.33 354 36.1 39.8 390 39.8 43.8

7/8 2.01 1.35 354 36.1 39.8 390 39.8 43.824 2.30 1.55 402 41.0 45.2 443 45.2 49.8

1 2.58 1.73 460 46.9 51.7 506 51.6 56.926 2.70 1.82 472 48.1 53.1 520 53.0 58.428 3.14 2.11 547 55.8 61.5 603 61.5 67.8

1 1/8 3.27 2.19 578 58.9 65.0 636 64.9 71.532 1 1/4 4.10 2.75 715 72.9 80.4 787 80.3 88.5

1 3/8 4.88 3.28 854 87.1 96.0 943 96.2 10636 5.18 3.48 904 92.2 102 997 102 112

Endurance Dyform® 34LR/PI

Note: all sizes Powerchecked

Endurance Dyform® 34XL

Endurance Dyform® 18/18PI

DiameterNominal Rope Length Mass

Min Breaking Force

mm in kg/m lbs/ft kNTons

(metric)Tons

(short)15 1.19 0.799 239 24.4 26.918 1.78 1.20 344 35.1 38.720 2.21 1.49 424 43.2 47.721 2.44 1.64 468 47.7 52.622 2.69 1.81 524 53.4 58.9

7/8 2.72 1.83 524 53.4 58.923 2.94 1.98 561 57.2 63.125 3.36 2.26 663 67.6 74.5

1 3.37 2.26 684 69.7 76.926 3.56 2.39 705 71.9 79.228 4.11 2.76 814 83.0 91.5

1 1/8 4.55 3.06 848 86.5 95.330 5.02 3.37 935 95.3 10532 1 1/4 5.57 3.74 1085 111 122

Endurance Dyform® 28 HML

Note: all sizes Powerchecked

DiameterNominal Rope Length Mass

Min Breaking Force

mm in kg/m lbs/ft kN Tons (metric)

Tons(short)

16 5/8 1.34 0.900 227 23.1 25.519 3/4 1.64 1.10 325 33.1 36.5

7/8 2.23 1.50 432 44.1 48.61 2.98 2.00 556 56.7 62.5

1 1/8 3.87 2.60 707 72.1 79.532 1 1/4 4.76 3.20 868 88.5 97.6

1 3/8 5.66 3.80 1060 108 11938 1 1/2 6.85 4.60 1240 126 139

1 5/8 7.89 5.30 1440 147 16244 1 3/4 9.23 6.20 1650 168 185

Constructex®

Note: all sizes Powerchecked

Note: all sizes Powerchecked

DiameterNominal Rope Length Mass

Min Breaking ForceEIP/1960 EEIP/2160

mm in kg/m lbs/ft kN Tons (metric)

Tons (short) kN Tons

(metric)Tons

(short) 3/8 0.427 0.287 86.2 8.79 9.69 86.2 8.79 9.69

10 0.470 0.316 89.2 9.10 10.0 92.8 9.46 10.411 7/16 0.570 0.383 110 11.2 12.4 114 11.6 12.812 0.679 0.456 128 13.1 14.4 133 13.6 14.9

1/2 0.759 0.510 144 14.7 16.2 149 15.2 16.713 0.796 0.535 150 15.3 16.9 156 15.9 17.514 0.923 0.620 174 17.7 19.6 182 18.6 20.5

9/16 0.961 0.646 181 18.5 20.3 190 19.4 21.416 5/8 1.17 0.798 226 23.0 25.4 236 24.1 26.518 1.50 1.01 286 29.2 32.1 299 30.5 33.619 3/4 1.68 1.13 318 32.4 35.7 333 34.0 37.420 1.86 1.25 353 36.0 39.7 369 37.6 41.522 2.26 1.52 427 43.5 48.0 446 45.5 50.1

7/8 2.33 1.56 427 43.5 48.0 446 45.5 50.124 2.68 1.80 508 51.8 57.1 531 54.1 59.7

1 3.00 2.01 569 58.0 64.0 595 60.7 66.926 3.14 2.11 596 60.8 67.0 623 63.5 70.028 3.65 2.45 691 70.5 77.7 723 73.7 81.3

1 1/8 3.85 2.58 720 73.4 80.9 753 76.8 84.630 4.19 2.81 794 81.0 89.2 830 84.6 93.332 1 1/4 4.71 3.16 903 92.1 101 944 96.3 10634 5.38 3.61 1020 104 115 1070 109 120

1 3/8 5.67 3.81 1080 110 121 1130 115 12736 6.03 4.05 1140 116 128 1200 122 13538 1 1/2 6.72 4.51 1270 130 143 1330 136 149

Endurance Dyform® 8/8PI

Note: all sizes Powerchecked

Diameter Nominal Rope Length

Min Breaking Force

EIP/1960

mm in kg/m lbs/ft kN Tons (metric)

Tons (short)

3/8 0.454 0.305 73.9 7.54 8.3110 0.500 0.336 84.4 8.61 9.4911 0.605 0.407 97.6 10.0 11.0

7/16 0.617 0.415 100 10.2 11.212 0.720 0.484 122 12.4 13.7

1/2 0.806 0.542 130 13.3 14.613 0.845 0.568 143 14.6 16.114 0.980 0.659 165 16.8 18.5

9/16 1.02 0.686 172 17.5 19.316 5/8 1.26 0.847 202 20.6 22.718 1.62 1.09 274 27.9 30.819 3/4 1.81 1.22 288 29.4 32.420 2.00 1.34 337 34.4 37.921 2.21 1.48 372 37.9 41.822 2.42 1.63 390 39.8 43.8

7/8 2.47 1.66 390 39.8 43.823 2.65 1.78 446 45.5 50.124 2.88 1.94 486 49.6 54.625 3.13 2.10 500 51.0 56.2

1 3.23 2.17 512 52.2 57.526 3.38 2.27 570 58.1 64.127 3.65 2.45 615 62.7 69.128 3.92 2.63 627 63.9 70.5

1 1/8 4.08 2.74 636 64.9 71.529 4.21 2.83 709 72.3 79.730 4.50 3.02 759 77.4 85.332 1 1/4 5.04 3.39 782 79.7 87.9

Diameter Nominal Rope Length Mass

Min Breaking ForceEIP/1960 EEIP/2160

mm in kg/m lbs/ft kN Tons (metric)

Tons (short) kN

Tons (metric)

Tons (short)

1/2 0.808 0.543 149 15.2 16.7 155 15.8 17.413 0.850 0.571 156 15.9 17.5 162 16.5 18.214 0.980 0.659 181 18.5 20.3 191 19.5 21.5

9/16 1.02 0.687 188 19.2 21.1 201 20.5 22.616 5/8 1.28 0.860 236 24.1 26.5 251 25.6 28.218 1.62 1.09 298 30.4 33.5 319 32.5 35.919 3/4 1.81 1.22 333 34.0 37.4 356 36.3 40.020 2.00 1.34 368 37.5 41.4 397 40.5 44.621 2.21 1.49 406 41.4 45.6 429 43.7 48.222 2.42 1.63 448 45.7 50.4 487 49.7 54.7

7/8 2.46 1.65 448 45.7 50.4 487 49.7 54.723 2.65 1.78 487 49.7 54.7 514 52.4 57.824 2.88 1.94 531 54.1 59.7 569 58.0 64.025 3.13 2.10 576 58.7 64.7 607 61.9 68.2

1 3.23 2.17 594 60.6 66.8 623 63.5 70.026 3.38 2.27 623 63.5 70.0 660 67.3 74.227 3.65 2.45 672 68.5 75.5 707 72.1 79.528 3.92 2.63 722 73.6 81.2 758 77.3 85.2

1 1/8 4.09 2.75 752 76.7 84.5 773 78.8 86.929 4.21 2.83 775 79.0 87.1 815 83.1 91.630 4.50 3.02 829 84.5 93.2 836 85.2 94.032 1 1/4 5.12 3.44 943 96.2 106 980 99.9 110

High Performance ® Boom Hoist Wire Ropes

Standard High Performance6x19 6x36 Dyform 34LR Dyform 28 HML Dyform 18 Dyform 6 Dyform 8 Constructex

Telescopic Mobile CraneAuxiliary Rope • • • • •Tower CraneMain Hoist Rope • • • • •Derricking Rope • • •Trolley Rope • • •Container CraneMain Hoist Rope • • • •Boom Hoist Rope • • •Trolley Rope • •Mobile Lattice Boom CraneMain Hoist Rope • • •Boom Hoist Rope • • • •Auxiliary Rope • • • • • •Dockside CraneMain Hoist Rope • • •Boom Hoist Rope • • •Overhead CraneMain Hoist Rope • • • •Steel Mill Ladle CraneMain Hoist Rope • • • •Offshore Pedestal CraneMain Hoist Rope • • •Whipline Rope • • •Boom Hoist Rope • • • •Unloader CraneMain Hoist Rope • • • •Boom Hoist Rope • • • •Closing Rope • • • •Racking Rope • •Piling CraneMain Hoist Rope •Pipe Handling Rope •

Wire Rope Application Guide for Cranes

Endurance Dyform® 34MAX

Note: all sizes Powerchecked

Note: all sizes Powerchecked

Diameter Nominal Rope Length Mass

Min Breaking ForceMAX

mm in kg/m lbs/ft kN Tons Tons 24 2.88 1.94 544 55.5 61.1

1 3.23 2.17 610 62.2 68.626 3.38 2.27 639 65.2 71.828 3.92 2.64 741 75.6 83.3

1 1/8 4.09 2.75 773 78.8 86.930 4.50 3.03 851 86.8 95.732 1 1/4 5.12 3.39 968 98.7 109

Note: all sizes Powerchecked

Endurance Dyform® 8 MAX

Note: all sizes Powerchecked

Note: all sizes Powerchecked

Diameter Nominal Rope Length Mass

Min Breaking Force

XL

mm in kg/m lbs/ft kN Tons (metric)

Tons (short)

16 5/8 1.35 0.908 272 27.7 30.619 3/4 1.95 1.31 382 39.0 42.9

1 3.20 2.15 638 65.1 71.726 3.39 2.28 658 67.1 74.028 3.91 2.63 751 76.6 84.4

1 1/8 4.06 2.73 773 78.8 86.929 4.38 2.94 829 84.5 93.232 1 1/4 5.02 3.37 980 99.9 110

Diameter Nominal Rope Length Mass

Min Breaking Force

MAX

mm in kg/m lbs/ft kN Tons (metric)

Tons (short)

1 3.36 2.26 684 69.7 76.926 3.56 2.39 705 71.9 79.328 4.11 2.76 818 83.4 91.9

1 1/8 4.55 3.06 848 86.5 95.332 1 1/4 5.57 3.74 1085 111 122