Table 14. When to Replace Wire Rope-Based on Number of Broken Wires

Standard Equipment
(lbs per ft)
Number Broken Wires
in Running Ropes
Number Broken Wires
in Standing Ropes
In One
Rope Lay
In One
In One
Rope Lay
At End
ASME/B30.2 Overhead & Gantry Cranes 12** 4 Not Specified
ASME/B30.4 Portal, Tower & Pillar Cranes 6** 3 3 2
ASME/B30.5 Crawler, Locomotive & Truck Retirement criteria based on number of broken Cranes Rotation Resistant Rope wires found in length of rope equal to 6 times rope diameter – 2 broken wires maximum, and 30 times rope diameter – 4 broken wires maximum.
Running Rope 6** 3 3 2
ASME/B30.6 Derricks 6** 3 3 2
ASME/B30.7 Base Mounted Drum Hoists 6** 3 3 2
ASME/B30.8 Floating Cranes & Derricks 6** 3 3 2
ASME/30.16 Overhead Hoists 12** 4 Not Specified
ANSI/A10.4 Personnel Hoists 6** 3 2** 2
ANSI/A10.5 Material Hoists 6** Not Specified

**Also remove for 1 valley break

Figure 43. A wire broken under a tensile load that exceeds its strength is recognized 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).