NCCCO Wire Rope Inspection and Replacement

Question 1

When inspecting wire rope on a crane, what are 'valley breaks' and why are they particularly serious?

Accepted Answer

Wire breaks occurring in the valleys between strands — they are hidden from easy view and indicate advanced fatigue requiring immediate removal from service

Answer

Surface breaks visible on the crown of each strand due to abrasion

Answer

Breaks caused by chemical corrosion along the rope's outer surface

Answer

Breaks found only at the end terminations of the rope

Question 2

Wire rope has a measured diameter of 0.94 inches but its nominal (rated) diameter is 1 inch. Should this rope be removed from service?

Accepted Answer

Yes — a reduction greater than 1/16 inch below nominal for 7/8-inch to 1-1/8-inch ropes requires removal per ASME B30.5

Answer

No — reduction in diameter is cosmetic and does not affect load capacity

Answer

Only if the reduction exceeds 1/8 inch below nominal

Answer

Only if accompanied by visible wire breaks

Question 3

What does 'bird-caging' in a wire rope indicate, and what action is required?

Accepted Answer

The outer strands have expanded outward from the core due to shock loading or severe reverse bending — the rope must be removed from service immediately

Answer

Normal rope stretch under heavy loads that disappears when the load is removed

Answer

Internal core slippage that can be corrected by re-tensioning the rope

Answer

A rope manufacturing defect visible only in new rope

Question 4

Which end termination is typically used for permanent attachment of wire rope to a crane drum or dead end anchor to achieve full rated breaking strength?

Accepted Answer

Swaged (pressed) or spelter socket terminations, which achieve 100% of the wire rope's rated breaking strength

Answer

Three-bolt wire rope clips (clamps), which are used for all permanent terminations

Answer

Simple loop-back with tape binding for light duty permanent connections

Answer

Wedge socket terminations, which achieve 70 to 75% of wire rope strength

Question 5

When installing wire rope clips (clamps) on a wire rope, what is the correct clip orientation rule?

Accepted Answer

Never saddle a dead horse — the clip saddle bears on the live (loaded) rope end and the U-bolt bears on the dead (short) end

Answer

The U-bolt bears on the live rope end for maximum grip

Answer

Clips may be oriented in any direction as long as the torque specification is met

Answer

Only one clip is required if it is a heavy-duty forged type

Question 6

How should wire rope be stored on a job site to prevent damage before being installed on a crane?

Accepted Answer

On reels or coils in a dry, covered area off the ground, away from chemicals and extreme heat, with end caps to prevent unraveling

Answer

Directly on the ground, covered with a tarp weighted at the edges

Answer

In tight figure-eight loops to save space and prevent the rope from tangling

Answer

Hanging vertically from a wall hook at one end of the coil