Although wire ropes are stable and reliable, they are not unbreakable. They can succumb to constant pressure and overuse and can snap while in use. When considering potential risks, it is vital to keep an eye open for unsafe wire ropes. Many problems cause wire ropes to break, and this article will go over some of the most common breaks. Safety is the most crucial aspect of any factory that operates overhead cranes or hoists. 
What will cause a wire rope to break?
- Wear in sections where hoist drums and sheave contact rope
- A lack of lubrication for extended periods
- Prolonged exposure to heat and moisture
- Constantly repeated bending— fatigue can happen during normal operating conditions
- Consistently neglecting manufacturers’ weight charts—overloading systems is the most common cause of breaks
- Crushing, dragging, or cutting rope because of mechanical abuse
- Spooling onto multi-layered drums causes crushing
- Using frozen or stiff ropes
- Improper installation will cause kinks
The problems listed above can mostly be avoided if operators practice proper rope maintenance procedures. Some issues cannot be avoided, and so frequent inspections must be done so users can know the full extent of their rope’s health.
Some wire rope users believe in a statutory life policy, which states that ropes be retired at predetermined times. Others go by a retirement clause, which allows cables to be used until deteriorated beyond a set point. Although some still practice statutory policies, regulators claim this policy is overly wasteful compared to the retirement clause.
Do not wait for your next accident. Be proactive with the health of your wire rope. Make sure to properly use ropes, meaning acquiring necessary rigging supplies, like nylon slings or wire rope sling. It is imperative you monitor your wire ropes and that they get retired before a problem or accident occurs.
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