When to Replace Wire Rope – Based on Number of Broken Wires


Number Broken Wires in Running Ropes Number Broken Wires in Standing Ropes
ANSI* Standard Equipment In One Rope Lay In One Strand In One Rope Lay At End Connection
B30.2 Overhead & Gantry Cranes 12 4 Not Specified Not Specified
B30.4 Portal, Tower & Pillar Cranes 6 3 3 2
B30.5 Crawler, Locomotive & Truck Cranes 6 3 3 2
B30.6 Derricks 6 3 3 2
B30.7 Base Mounted Drum Hoists 6 3 3 2
B30.8 Flotaing Cranes & Derricks 6 3 3 2
B30.16 Overhead Hoists 12 4 Not Specified Not Specified
A10.4 Personnel Hoists 6** 3 2** 2
A10.5 Material Hoists 6** Not Specified Not Specified Not Specified

* American National Standards Institute
** Also remove for 1 valley break.

necking down of a wire shear-tensile fracture on wire rope
z shaped fatigue break of wire rope squared off break of wire rope

A wire broken under a tensile load that exceeds its strength by
the “cup and cone” configuration at the fracture point
(a). The necking down of the wire at this point shows
that failure occurred while the wire retained its ductility.
Shear-tensile fracture (b) occurs in wire subjected to a combination
of transverse and axial loads. Fatigue breaks are usually characterized
by squared-off ends perpendicular to the wire either straight
across or Z-shaped (c & d).