Wire Rope, Drums and Fittings, including Standing Ropes Tackle Regulations, Part IV, Rope, 22. (1) No rope shall be used in the processes unless: (1-a) it is of suitable quality and free from patent defect; and (1-b) in the case of wire rope, it has been examined and tested by a competent person in the manner set out in Schedule I. (2) Every wire rope in general use in the processes shall be inspected by a competent person once at least in every three months, except that after any wire in such rope has broken it shall be inspected once at least in every month. (3) No wire rope shall be used in the processes if, in any length of eight diameters the total number of visible broken wires exceeds 10 per cent of the total number, or the rope shows signs of excessive wear, corrosion or other defect that, in the opinion of the person who inspects it or of any inspector, renders it unfit for use. Tips Examples of Damage to Wire Rope This can also be found in the Rigging Manual Lubrication The single most important operational check to be made on hoisting and rigging equipment is the rope and rigging inspection. Factors such as abrasion, wear, fatigue, corrosion, improper reeving and kinking are often of greater significance in determining the usable lift of wire rope than are strength factors based on new rope conditions. There are certain points along any given rope which should receive more attention than others, since some areas will usually be subjected to greater internal stresses, or to greater external forces and hazards. Carefully select the most critical points for close inspection, points where failure would be most likely to occur. The same critical points on each installation should be compared at each succeeding inspection. All wire rope in continuous service should be observed during normal operation and visually as per the schedule above. A complete and thorough inspection of all ropes in use must be made as below and all rope which has been idle for a period of a month or more should be given a thorough inspection before it is put back into service. All inspections should be the responsibility of and be performed by an appointed competent person who makes a complete report of the rope condition. A record of each rope should be kept (include certificate number, date of fitting, size, construction, length and defects found during inspections). Example of Wire Rope inspection Log, click here. Any deterioration, resulting in a suspected loss of original rope strength, should be carefully examined and a determination made as to whether further use of the rope would constitute a safety hazard. This is particularly true if the rope has been stressed, shock-loaded, jumped a sheave, run around a sharp bend or otherwise compromised. Only by inspection can it be determined whether or not the rope should be replaced. The inspector must decide: - if the rope's condition presents any possibility of failure, and - if the rate of deterioration of the rope is such that it will remain in safe condition until the next scheduled inspection. When inspecting the rope give every inch of its length equal care as serious deterioration frequently occurs in localized positions. The estimate of the rope's condition must be made at the section showing the maximum deterioration. If you, as the inspector, consider it necessary to replace a rope cost is not a factor. Should there be any doubt as to whether or not a rope is fit for use, it should be replaced at once. Never risk danger to life or damage to property by taking a chance. When a rope has been condemned, it should be destroyed at once or cut up into short lengths so that it cannot be used for hoisting purposes. Cut off any fittings and dispose of them. Under no circumstances should a condemned rope be saved "Just in Case". If it is poor enough to be condemned it is of no further use. A Few Tips: - Hose off the deck where you will be working to remove as much grit and abrasive material as possible. - If possible, completely remove the wire from the drum. If not, run as much of the wire off the drum as possible. Flake the wire over your working area. - Be careful not to kink the wire. It may be necessary to use "Frenchmen" to avoid kinks. - Modern wire is usually preformed. This, and lubrication, makes it difficult to see broken wires. The easiest way to find broken wires is to wear a pair of heavy-duty gloves and run both hands around and along the entire wire. If there is a broken wire it will usually catch the glove. - Another way to find broken wires. - If you find a broken or damaged wire, clean off an area about 1 metre on either side of the damage. Carefully examine the damage and the surrounding area. - At random, select areas of the wire to clean off and carefully inspect. Use these areas to measure the wire diameter. Pay particular attention to areas where the wire rests on sheaves when the crane is not in use as you may find greater wear here. - Open the wire to inspect the inside for damage, lubrication, condition of the core etc.  (You cannot do this with non-rotating wire). - Diligently clean and inspect all thimbles, sleeves, splices, sockets and end-fittings. - Measure rope diameter. - Measure rope lay. - Renew any tags or stamps that identify the wire. - Any damage to the wire may have caused, or have been caused by, damage on the sheaves or drums. If necessary to replace a damaged wire ensure you check the sheaves and drums before reeving the new wire. - With the wire off the drum clean and inspect the entire drum including the securing mechanism and any built in grooves (use your groove gauge for this). Even though both these gauges properly follow groove contours, when used side-by-side they indicate grooves are too close and that the "Drum Pitch" is less than the rope diameter. Two gauges which overlap in this manner reveal that wraps of rope will scrub when spooling on to or off the drum. - This is also an ideal opportunity to take photos of, or sketch, the drum with no wire on it and the securing mechanism. Some securing mechanisms are difficult to work with or of unusual construction. Photos and sketches will greatly assist in the future. Example, click here. - Make notes of what you found, where you found it and what, if anything, you did about it. - If you find a broken wire ensure you note when it must be re-examined. - When you re-reeve the wire, lubricate it! - Watch how the wire spools on the drum. Spooling is the characteristic of a rope which affects how it wraps onto and off a drum. Spooling is affected by the care and skill with which the first layer of wraps is applied on drums with two or more layers. Wraps should be tight. It is important to examine a rope for kinks or other damage when loose or irregular spooling has been observed. - If the wire has been spliced on board it must be removed from service and sent to a testing facility for recertification. Under no circumstances should you use hand-spliced wire without a test certificate. - Wire Rope Industries web page Measuring Rope Diameter. - Wire Rope Industries web page Measuring Rope Lay. - Wire Rope Industries web page Finding Broken Wires. - Wire Rope Industries web page Internal Rope Examination. - Wire Rope Industries web page End Attachments. - Wire Rope Industries web page Evaluating Drums. - Wire Rope Industries web page Critical Inspection Points. Refer to the Construction Safety Association of Ontario "Rigging Manual", Chapter 1, Wire Rope. Lubrication The following information is taken from the Wire Rope Industries Web Site. During manufacture steel wire ropes are thoroughly lubricated internally and externally with lubricants specially suited to the requirements of wire rope lubrication and protection. When a wire rope bends around a sheave or a drum the individual wires and strands move in relation to each other to adjust themselves to the curvature assumed by the rope. Thus a well lubricated rope permits full and unrestricted movement of the wires and strands with a consequent minimum of fatigue and frictional wear. In addition to providing internal lubrication for free movement of the wires the lubricant also provides protection against rust and corrosion. Presence of these, if given time, will cause serious deterioration to both steel wires and fibre core. Fibre cores are specially treated during manufacture in the cordage factory to remove excess and undesirable moisture. While still in the fibre state they are thoroughly impregnated with a specially compounded lubricant which preserves the fibres and keeps them pliable. This treatment also adds further lubrication to the strands during the early part of rope service. The internal pressures set up in a rope while in use tend to force the lubricant from both the core and the rope strands. This has the effect of reducing the quantity of lubricant contained in the rope. Consequently for maximum rope life the lubrication applied during manufacture should be supplemented by periodic lubrication during service. Whether stationary or in motion, steel wire ropes must be protected from corrosion, and when in motion must be lubricated to minimize wear between the metal-to-metal (wire-to-wire) surrounding surfaces. During manufacture a lubricant which will satisfy both these requirements at least for a time is built into the strands of wire and into the core. Exposure to the elements, normal rope operation over sheaves and on and off drums will gradually deplete and contaminate the lubricant. In some applications, where the ropes continually work through dirt and grit, in-service lubrication may not improve rope life. Most ropes however should be lubricated at intervals depending on the type of service to minimize corrosion and wear and extend rope life. A used rope should be thoroughly cleaned prior to the application of new lubricant. Wire brushes can do an effective job. In some instances it may be necessary to soften the old lubricant and accumulation of dirt with a penetrating oil. A lubricant suited to the conditions under which the rope is operating should then be applied. Several methods are suggested, and the one most suited to the installation and lubricant being used may be chosen. It is better to lubricate lightly and frequently than heavily and infrequently. A suitable rope lubricant should have the following properties: 1) Freedom from acids and alkalies. 2) Sufficient adhesive strength to stay on the rope without throw-off at maximum rope speed. 3) Ability to penetrate between strands and reach the core. 4) Non-solubility under conditions of rope use. 5) Resistance to oxidation. 6) High film strength is an advantage. When a wire rope is taken out of service for storage and possible future use it should first be cleaned, then lubricated. The rope should then be covered and stored in a dry location and protected against mechanical damage. Manufacturer's Warehouse web site about Wire Rope Lubrication