18 Brown and Perkins, Inc. Wire Rope Failure Types and Conditions Broken Wires Check for overloads, tight grooves, fast starts or stops, wrong rope type or size, worn sheaves, abnormal forces during install. Eventually, all wire rope will fail in this mode. Birdcaging Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires cannot return to their original position. Damaged Fittings Usually occurs when a fitting gets stopped while travelling over uneven surfaces or is damaged by an impact from another fitting. Remove from service immediately. Rotational Damage Happens when the load spins out of control against the construction wind of the rope. If the strands cannot return to their original position when relaxed, replace the rope. Fatigue Fractures Usually seen when rope was subjected to heavy load while run over small sheaves. Most wires are breaking in the valleys between the strands. Pig Tailing Results from the rope being pulled around an object of too small a diameter for the rope. Drum Crushing …and spiraling in a winch line. This is caused by small drums, high loads and multiple layer uncontrolled winding conditions frequently found on winches. Dog Leg If severe, remove rope from service. If minor and doesn’t exhibit strand distortion and/or cannot be observed when under tension, mark it and keep it under observation. Popped Core Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires are trapped and cannot return to their original position. Kinked or Crushed Wires This condition prohibits the free movement of wires within the rope. The kink must be cut out or the entire rope replaced. Wire Rope Failure Types and Conditions Broken Wires Check for overloads, tight grooves, fast starts or stops, wrong rope type or size, worn sheaves, abnormal forces during install. Eventually, all wire rope will fail in this mode. Birdcaging Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires cannot return to their original position. Damaged Fittings Usually occurs when a fitting gets stopped while travelling over uneven surfaces or is damaged by an impact from another fitting. Remove from service immediately. Rotational Damage Happens when the load spins out of control against the construction wind of the rope. If the strands cannot return to their original position when relaxed, replace the rope. Fatigue Fractures Usually seen when rope was subjected to heavy load while run over small sheaves. Most wires are breaking in the valleys between the strands. Pig Tailing Results from the rope being pulled around an object of too small a diameter for the rope. Drum Crushing …and spiraling in a winch line. This is caused by small drums, high loads and multiple layer uncontrolled winding conditions frequently found on winches. Dog Leg If severe, remove rope from service. If minor and doesn’t exhibit strand distortion and/or cannot be observed when under tension, mark it and keep it under observation. Popped Core Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires are trapped and cannot return to their original position. Kinked or Crushed Wires This condition prohibits the free movement of wires within the rope. The kink must be cut out or the entire rope replaced. Wire Rope Failure Types and Conditions Broken Wires Check for overloads, tight grooves, fast starts or stops, wrong rope type or size, worn sheaves, abnormal forces during install. Eventually, all wire rope will fail in this mode. Birdcaging Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires cannot return to their original position. Damaged Fittings Usually occurs when a fitting gets stopped while travelling over uneven surfaces or is damaged by an impact from another fitting. Remove from service immediately. Rotational Damage Happens when the load spins out of control against the construction wind of the rope. If the strands cannot return to their original position when relaxed, replace the rope. Fatigue Fractures Usually seen when rope was subjected to heavy load while run over small sheaves. Most wires are breaking in the valleys between the strands. Pig Tailing Results from the rope being pulled around an object of too small a diameter for the rope. Drum Crushing …and spiraling in a winch line. This is caused by small drums, high loads and multiple layer uncontrolled winding conditions frequently found on winches. Dog Leg If severe, remove rope from service. If minor and doesn’t exhibit strand distortion and/or cannot be observed when under tension, mark it and keep it under observation. Popped Core Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires are trapped and cannot return to their original position. Kinked or Crushed Wires This condition prohibits the free movement of wires within the rope. The kink must be cut out or the entire rope replaced. Wire Rope Failure Types and Conditions Broken Wires Check for overloads, tight grooves, fast starts or stops, wrong rope type or size, worn sheaves, abnormal forces during install. Eventually, all wire rope will fail in this mode. Birdcaging Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires cannot return to their original position. Damaged Fittings Usually occurs when a fitting gets stopped while travelling over uneven surfaces or is damaged by an impact from another fitting. Remove from service immediately. Rotational Damage Happens when the load spins out of control against the construction wind of the rope. If the strands cannot return to their original position when relaxed, replace the rope. Fatigue Fractures Usually seen when rope was subjected to heavy load while run over small sheaves. Most wires are breaking in the valleys between the strands. Pig Tailing Results from the rope being pulled around an object of too small a diameter for the rope. Drum Crushing …and spiraling in a winch line. This is caused by small drums, high loads and multiple layer uncontrolled winding conditions frequently found on winches. Dog Leg If severe, remove rope from service. If minor and doesn’t exhibit strand distortion and/or cannot be observed when under tension, mark it and keep it under observation. Popped Core Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires are trapped and cannot return to their original position. Kinked or Crushed Wires This condition prohibits the free movement of wires within the rope. The kink must be cut out or the entire rope replaced. Wire Rope Failure Types and Conditions Broken Wires Check for overloads, tight grooves, fast starts or stops, wrong rope type or size, worn sheaves, abnormal forces during install. Eventually, all wire rope will fail in this mode. Birdcaging Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires cannot return to their original position. Damaged Fittings Usually occurs when a fitting gets stopped while travelling over uneven surfaces or is damaged by an impact from another fitting. Remove from service immediately. Rotational Damage Happens when the load spins out of control against the construction wind of the rope. If the strands cannot return to their original position when relaxed, replace the rope. Fatigue Fractures Usually seen when rope was subjected to heavy load while run over small sheaves. Most wires are breaking in the valleys between the strands. Pig Tailing Results from the rope being pulled around an object of too small a diameter for the rope. Drum Crushing …and spiraling in a winch line. This is caused by small drums, high loads and multiple layer uncontrolled winding conditions frequently found on winches. Dog Leg If severe, remove rope from service. If minor and doesn’t exhibit strand distortion and/or cannot be observed when under tension, mark it and keep it under observation. Popped Core Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires are trapped and cannot return to their original position. Kinked or Crushed Wires This condition prohibits the free movement of wires within the rope. The kink must be cut out or the entire rope replaced. Wire Rope Failure Types and Conditions Broken Wires Check for overloads, tight grooves, fast starts or stops, wrong rope type or size, worn sheaves, abnormal forces during install. Eventually, all wire rope will fail in this mode. Birdcaging Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires cannot return to their original position. Damaged Fittings Usually occurs when a fitting gets stopped while travelling over uneven surfaces or is damaged by an impact from another fitting. Remove from service immediately. Rotational Damage Happens when the load spins out of control against the construction wind of the rope. If the strands cannot return to their original position when relaxed, replace the rope. Fatigue Fractures Usually seen when rope was subjected to heavy load while run over small sheaves. Most wires are breaking in the valleys between the strands. Pig Tailing Results from the rope being pulled around an object of too small a diameter for the rope. Drum Crushing …and spiraling in a winch line. This is caused by small drums, high loads and multiple layer uncontrolled winding conditions frequently found on winches. Dog Leg If severe, remove rope from service. If minor and doesn’t exhibit strand distortion and/or cannot be observed when under tension, mark it and keep it under observation. Popped Core Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires are trapped and cannot return to their original position. Kinked or Crushed Wires This condition prohibits the free movement of wires within the rope. The kink must be cut out or the entire rope replaced. Wire Rope Failure Types and Conditions Broken Wires Check for overloads, tight grooves, fast starts or stops, wrong rope type or size, worn sheaves, abnormal forces during install. Eventually, all wire rope will fail in this mode. Birdcaging Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires cannot return to their original position. Damaged Fittings Usually occurs when a fitting gets stopped while travelling over uneven surfaces or is damaged by an impact from another fitting. Remove from service immediately. Rotational Damage Happens when the load spins out of control against the construction wind of the rope. If the strands cannot return to their original position when relaxed, replace the rope. Fatigue Fractures Usually seen when rope was subjected to heavy load while run over small sheaves. Most wires are breaking in the valleys between the strands. Pig Tailing Results from the rope being pulled around an object of too small a diameter for the rope. Drum Crushing …and spiraling in a winch line. This is caused by small drums, high loads and multiple layer uncontrolled winding conditions frequently found on winches. Dog Leg If severe, remove rope from service. If minor and doesn’t exhibit strand distortion and/or cannot be observed when under tension, mark it and keep it under observation. Popped Core Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires are trapped and cannot return to their original position. Kinked or Crushed Wires This condition prohibits the free movement of wires within the rope. The kink must be cut out or the entire rope replaced. Wire Rope Failure Types and Conditions Broken Wires Check for overloads, tight grooves, fast starts or stops, wrong rope type or size, worn sheaves, abnormal forces during install. Eventually, all wire rope will fail in this mode. Birdcaging Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires cannot return to their original position. Damaged Fittings Usually occurs when a fitting gets stopped while travelling over uneven surfaces or is damaged by an impact from another fitting. Remove from service immediately. Rotational Damage Happens when the load spins out of control against the construction wind of the rope. If the strands cannot return to their original position when relaxed, replace the rope. Fatigue Fractures Usually seen when rope was subjected to heavy load while run over small sheaves. Most wires are breaking in the valleys between the strands. Pig Tailing Results from the rope being pulled around an object of too small a diameter for the rope. Drum Crushing …and spiraling in a winch line. This is caused by small drums, high loads and multiple layer uncontrolled winding conditions frequently found on winches. Dog Leg If severe, remove rope from service. If minor and doesn’t exhibit strand distortion and/or cannot be observed when under tension, mark it and keep it under observation. Popped Core Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires are trapped and cannot return to their original position. Kinked or Crushed Wires This condition prohibits the free movement of wires within the rope. The kink must be cut out or the entire rope replaced. Wire Rope Failure Types and Conditions Broken Wires Check for overloads, tight grooves, fast starts or stops, wrong rope type or size, worn sheaves, abnormal forces during install. Eventually, all wire rope will fail in this mode. Birdcaging Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires cannot return to their original position. Damaged Fittings Usually occurs when a fitting gets stopped while travelling over uneven surfaces or is damaged by an impact from another fitting. Remove from service immediately. Rotational Damage Happens when the load spins out of control against the construction wind of the rope. If the strands cannot return to their original position when relaxed, replace the rope. Fatigue Fractures Usually seen when rope was subjected to heavy load while run over small sheaves. Most wires are breaking in the valleys between the strands. Pig Tailing Results from the rope being pulled around an object of too small a diameter for the rope. Drum Crushing …and spiraling in a winch line. This is caused by small drums, high loads and multiple layer uncontrolled winding conditions frequently found on winches. Dog Leg If severe, remove rope from service. If minor and doesn’t exhibit strand distortion and/or cannot be observed when under tension, mark it and keep it under observation. Popped Core Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires are trapped and cannot return to their original position. Kinked or Crushed Wires This condition prohibits the free movement of wires within the rope. The kink must be cut out or the entire rope replaced. Wire Rope Failure Types and Conditions Broken Wires Check for overloads, tight grooves, fast starts or stops, wrong rope type or size, worn sheaves, abnormal forces during install. Eventually, all wire rope will fail in this mode. Birdcaging Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires cannot return to their original position. Damaged Fittings Usually occurs when a fitting gets stopped while travelling over uneven surfaces or is damaged by an impact from another fitting. Remove from service immediately. Rotational Damage Happens when the load spins out of control against the construction wind of the rope. If the strands cannot return to their original position when relaxed, replace the rope. Fatigue Fractures Usually seen when rope was subjected to heavy load while run over small sheaves. Most wires are breaking in the valleys between the strands. Pig Tailing Results from the rope being pulled around an object of too small a diameter for the rope. Drum Crushing …and spiraling in a winch line. This is caused by small drums, high loads and multiple layer uncontrolled winding conditions frequently found on winches. Dog Leg If severe, remove rope from service. If minor and doesn’t exhibit strand distortion and/or cannot be observed when under tension, mark it and keep it under observation. Popped Core Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires are trapped and cannot return to their original position. Kinked or Crushed Wires This condition prohibits the free movement of wires within the rope. The kink must be cut out or the entire rope replaced. Broken Wires Check for overloads, tight grooves, fast starts or stops, wrong rope type or size, worn sheaves, abnormal forces during install. Eventually, all wire rope will fail in this mode. Birdcaging Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires cannot return to their original position. Remove and replace. Damaged Fittings Usually occurs when a fitting gets stopped while travelling over uneven surfaces or is damaged by an impact from another fitting. Remove from service immediately. Rotational Damage Happens when the load spins out of control against the construction wind of the rope. If the strands cannot return to their original position when relaxed, replace the rope. Fatigue Fractures Usually seen when rope was subjected to heavy load while run over small sheaves. Most wires break in the valleys between the strands. Remove from service. Pig Tailing Results from the rope being pulled around an object of too small a diameter for the rope. Replace the rope. Drum Crushing …and spiraling in a winch line. This is caused by small drums, high loads and multiple layer uncontrolled winding conditions frequently found on winches. If strands or wires cannot move, replace rope. Dog Leg If severe, remove rope from service. If minor and doesn’t exhibit strand distortion and/or cannot be observed when under tension, mark it and keep it under observation. Popped Core Caused by a sudden release in rope tension or a build-up of twist in the rope. Strands and wires are trapped and cannot return to their original position. Remove from service. Kinked or Crushed Wires This condition prohibits the free movement of wires within the rope. The kink must be cut out or the entire rope replaced.