Wire rope and synthetic slings are the critical link between the crane and the load. A failure during a lift can kill. The good news: wire rope degrades visibly and predictably, giving ample warning if you know what to look for.
What to Inspect Before Every Lift
Run your hand along the full length of the wire rope to feel for broken wires, kinks, birdcaging, or areas of reduced diameter. Count visible broken wires — in the valley between strands and at terminations, six randomly distributed broken wires in one rope lay, or three broken wires in one strand in one lay are removal criteria. Never lift with visible kinks, birdcages, or flattened sections.
Inspection at Terminations
The most common failure point is at termination points — swaged fittings, wedge sockets, and socket attachments. Inspect these carefully for cracks, distortion, and signs of wire withdrawal. Terminations should be marked with the manufacturer's identification and rated capacity. Any unmarked or damaged termination must be replaced before the next lift.
When to Retire Wire Rope
Retire wire rope when: broken wires reach removal criteria; diameter is reduced below nominal diameter by more than allowable; strands have been displaced (birdcaging); kinking, crushing, or heat damage is evident; corrosion is visible; or terminations show signs of deterioration. Keep inspection records for all rigging equipment — a documented history protects you in the event of an incident investigation.