Wire Rope Sling Inspection
What You Need to Look At Before Every Lift
By: Jimmy Laub - Fulcrum Lifting
Wire rope slings are used in a wide variety of lifting, hoisting, and rigging applications because of its strength and versatility. But like any piece of equipment, it has a service life, and that depends heavily on inspection and care.
At Fulcrum Lifting, we regularly provide training and help customers identify when wire rope slings need to be removed from service. Here’s a practical guide to help you spot the most common issues before they turn into serious failures.
Why Wire Rope Sling Inspection Matters
A failed wire rope sling can result in dropped loads, damaged equipment, and potentially serious injury. That’s why OSHA and ASME standards require frequent inspections, not just periodic checks, but visual inspections before each use.
Common Wire Rope Sling Damage to Look For
1. Sling Tag Illegible or missing
What it is:
The sling tag is the identification tag which includes information such as the manufacturer, rated load for at least one hitch type, and sling identification like a serial number. The tag will also include the number of legs for a bridle assembly.
What causes it:
- Wear and tear
- Improper sling storage
Why it’s dangerous:
Using a wire rope sling without the proper identification poses a significant safety risk due to the missing critical information regarding the sling capacity and proper usage.
2. Birdcaging
What it is:
Strands of the rope become untwisted and bulge outward, often resembling a birdcage.
What causes it:
- Shock loading
- Improper handling or spooling
- Sudden release of tension
Why it’s dangerous:
Birdcaging indicates internal damage. Even if the rope appears intact in some areas, it’s no longer safe for lifting.
3. Broken Wires
What to look for:
Count visible broken wires in one rope lay (the length it takes for one strand to make a full revolution around the rope).
Retirement criteria:
- 6 or more broken wires in one lay
- 3 or more in a single strand in one lay
- 1 or more broken wire at the rope’s termination
Note: Wires that are cracked, worn, or visibly fraying also count.
4. Kinks and Bends
What it looks like:
A loop or sharp bend that has been pulled tight, permanently deforming the rope.
Why it’s unsafe:
Kinks change the internal structure and tension of the wire strands. The rope’s strength and reliability are significantly compromised.
5. Crushing and Flattening
What to look for:
Areas of the rope that appear flattened, pinched, or unusually wide.
What causes it:
- Improper D/d ratio
- Improper winding or storage
- Overloading
Danger:
Crushed rope can have internal core damage that’s not visible on the surface. These ropes should always be removed from service.
Summary: When to Retire Wire Rope
|
Condition |
Remove from Service? |
|
Bird caging |
✅ Yes |
|
10+ Broken Wires in One Lay |
✅ Yes |
|
5+ Broken Wires in One Strand |
✅ Yes |
|
Kinks or Loops |
✅ Yes |
|
Crushed or Flattened Sections |
✅ Yes |
|
Corrosion or Heat Damage |
✅ Yes |
Need a Replacement?
If your wire rope is damaged or worn out, Fulcrum Lifting can fabricate custom wire rope assemblies to match your needs. Whether it’s a crane hoist rope, pendant line, winch cable, or wire rope sling, we stock a wide range of fittings and wire sizes for fast turnaround.
Contact us to learn more or request a quote for a replacement assembly.