Types of Wire Rope Damage and How to Prevent Them

Wire rope often suffers damage due to factors such as improper use or extreme working environments.

Common Causes of Wire Rope Damage

Wire rope is a critical component in many industries, especially for lifting and pulling operations. However, improper use or harsh environmental conditions often lead to rope damage.

Understanding the common causes of damage, the types of failures that occur, and prevention methods is essential to maintain safety and operational efficiency.

Overloading that Damages the Rope Strands

Using a wire rope beyond its rated capacity can cause serious strand damage. Overloading may lead to individual wires breaking or permanent deformation of the rope’s structure.

Shock loads and excessive vibration also accelerate rope deterioration.

Abrasion on Rough or Irregular Surfaces

Friction between the wire rope and rough or uneven surfaces causes abrasion.

This wear erodes the outer wires, reduces diameter, and weakens overall rope strength. Severe abrasion can result in a significant reduction in rope diameter.

Corrosion from Environmental Exposure

Exposure to high humidity, seawater, or corrosive chemicals leads to rust and corrosion.

Corrosion damages the internal wire structure, reduces tensile strength, and increases the risk of failure under load.

Improper Handling and Storage

Poor handling—such as sudden pulls or accidental loops—can deform the rope. Storing rope in damp or corrosive environments without protection accelerates damage.

Many damage cases stem from mishandling that creates kinks or knots, compromising rope integrity.

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Common Types of Damage Found in Wire Rope

Wire rope is a critical component in various lifting and rigging applications. Over time and with use, wire rope can develop different types of damage that affect its performance.

Below are some of the common types of damage encountered in wire rope.

Broken Individual Wires

Broken or fractured individual wires are an early indicator of wire rope damage. This typically results from material fatigue due to repeated or excessive loads, as well as abrasion.

If the number of broken wires exceeds the tolerance limits specified by safety standards, the wire rope must be removed from service and replaced.

Flattening on the Wire Strand Surface

Flattening on the wire strand surface occurs when the wire rope is subjected to excessive pressure or continuous abrasion against a hard surface in one specific area.

This leads to permanent deformation and reduces the rope’s flexibility and strength. Such shape changes often result from uneven working loads.

Severe Corrosion on the Wire Rope Body

Severe corrosion can cause wire strands to flake off or produce debris from the eroded wires, indicating significant material loss and increasing the risk of structural failure.

Rust acts like a toxin that can destroy the internal components of the wire rope, thereby reducing its strength.

Crushing from Excessive Pressure

Crushing occurs when the wire rope is subjected to pressure beyond its capacity, causing deformation of its internal structure. This reduces the rope’s load-bearing ability and increases the risk of failure.

Damage to Thimbles and Clips

Accessories such as thimbles and clips used to secure the ends of wire ropes can also sustain damage. Damage to these components can reduce the effectiveness of the connection and increase the risk of failure during operation. Improper handling often contributes to damage in thimbles and clips.

Table of Wire Rope Damage Types and Their Causes

Type of Damage	Common Causes	Impact
Individual Wire Fracture	Material fatigue, repeated loading, overloading	Reduced strength, risk of failure
Flattening on Wire Strands	Excessive pressure, continuous friction at one point	Permanent deformation, reduced flexibility
Severe Corrosion with Layer Peeling	Exposure to moisture, corrosive environments, chemical exposure	Material loss, structural failure risk
Crushing Due to High Pressure	Pressure exceeding the wire rope’s capacity	Internal structural deformation, reduced durability
Damage to Thimbles and Clips	Overuse, improper handling	Decreased connection effectiveness, operational failure risk

Prevention Guidelines to Minimize Damage

Preventing damage to wire ropes is essential to ensure safe and efficient lifting and rigging operations.

By implementing the right preventive measures, you can extend the service life of wire ropes and reduce the risk of accidents. Below is a step-by-step guide to help minimize wire rope damage.

Daily Inspection Steps

Daily visual inspections are mandatory before using wire ropes to detect signs of damage such as broken wires, corrosion, or deformation. Routine inspections help identify problems early before failures occur. These inspections should be carried out by competent personnel to ensure accurate, detailed, and reliable results.

Visual Check: Look for signs of broken wires, rust, or deformation.
Feel the Surface: Detect any rough or uneven areas that may indicate internal damage.
Document the Findings: Record all inspection results in a log for future reference.

Proper Lubrication and Storage

Using wire ropes that are coated with lubricant or anti-corrosion material is a smart investment, as it helps protect against damaging environments. Prepare a dry, sheltered storage area to prevent direct exposure to corrosive elements. Proper lubrication is essential to keep wire ropes safe and high-performing.

Use the Right Lubricant: Choose lubricants recommended by the wire rope manufacturer.
Store in a Dry Area: Avoid storing wire ropes in damp or wet locations.
Protect from Sunlight: UV exposure can degrade wire rope materials over time.

Avoiding Overloading in Lifting Operations

Always ensure that the load being lifted does not exceed the maximum capacity of the wire rope. Use load monitoring devices if necessary to track weight in real-time. Operating beyond the wire rope's rated capacity can lead to serious damage.

Check Load Capacity: Make sure you know the wire rope’s safe working load (SWL).
Use Load Monitoring Tools: Utilize load indicators to monitor load weight accurately.
Never Exceed the Limit: Avoid lifting loads that surpass the wire rope’s capacity.

Preventive Maintenance with Lubrication

Applying specialized lubricant regularly is a must-do routine to support the performance of wire ropes. Lubrication helps reduce friction and protects the wire rope from corrosion.

Schedule Lubrication: Set a regular schedule for lubricating your wire rope.
Use the Right Lubricant: Choose a lubricant suited to your working environment.
Ensure Even Application: Apply lubricant evenly across the entire wire rope surface.

Conclusion

Wire rope damage can result from various factors such as overloading, friction, corrosion, and improper handling.

To ensure reliability and safety during use, it is crucial to carry out routine inspections. Inspections are key to detecting early signs of failure and preventing potential accidents.

Maintaining wire rope in optimal condition also depends on choosing high-quality products. With SpanSet wire ropes, you not only receive reliable products but also expert technical support ready to assist you.

Feel free to consult with us regarding specifications, usage, and maintenance tailored to your needs. Contact us for more information!