WIRE ROPE MISHANDLING/DEFORMATIONS

Figure 1

A wire broken under a tensile load that exceeds its strength is recognized by the
“cup and cone” configuration at the fracture point (a). The necking down of the
wire at this point shows that failure occurred while the wire retained it
ductility. Shear-tensile fracture (b) occurs in wire subjected to a combination of
transverse and axial loads. Fatigue breaks are usually characterized by squared-
off ends perpendicular to the wire either straight across or Z-shaped (c&d).

Additional Discard Criteria based on damage/deformation/overload:

Warning: For safety reasons crane ropes have to be discarded if showing one of the
following criteria.

• Number of wire breaks as defined in table Discard Criteria

• (fig.2) Basketlike distortion

• (fig.3) Loosening of rope structure (inner core)

 • (fig.4) Kinks, bends or local crushing (also called “dog-leg”)

The following conditions (figs 11 & 12) can be caused by a sudden release of
tension and the resulting rebound of the rope from its overloaded condition. The
strands and wires will not return to their original position. These conditions can
also result from the rope operating through a tight groove.

• (Fig.5) Improper handling, rope rotation, sudden release of a load or core

slippage can cause a “popped core”.

• (Fig.6) A “birdcage” is damage to the rope structure due to a sudden release

of the load.
 • (Fig.7) This is an example of a wire rope that has jumped a sheave. The
deformation is in the shape of a curl – as if it had been around a circular
shaft. On close examination, the wires show two types of breaks – the normal
tensile cup and cone and the shear break which appear as having been cut
with a cold chisel on an angle (see fig. 1).

If special rope damage is found, the cause has to be determined and eliminated
before a new rope is installed.

If in doubt, discard rope or consult our company for further assistance.