LFT/General/TBT-LFT-016

Wire Rope Inspection and Rejection

Lifting OperationsGeneralWire Rope Inspection and Rejection

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Wire Rope Inspection and Rejection

Toolbox Talk Record

Ref: TBT-LFT-016  |  Issue: 1  |  Date: March 2026
PresenterProject
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What?

  • Wire ropes are used as crane hoist ropes, lifting slings, and guy ropes under heavy loads.
  • LOLER 1998 requires all lifting accessories including wire ropes to be thoroughly examined at specified intervals.
  • Broken wires are the most visible sign of deterioration — rejection criteria depend on wire count and pattern.
  • Corrosion reduces the cross-sectional area of wires, weakening the rope below its rated capacity.
  • Kinking, bird-caging, and crushing are mechanical defects that require immediate rejection of the rope.
  • Wire rope diameter must be measured — a 10% reduction from nominal diameter indicates serious wear.
  • Heat damage from welding sparks or proximity to hot surfaces weakens the steel and requires rejection.
  • Rope terminations including ferrules, thimbles, and swaged fittings must be inspected for damage.
  • Pre-use visual inspections by the user supplement but do not replace scheduled thorough examinations.
  • A defective wire rope can fail without warning during a lift, causing fatal consequences.

Why?

Prevent rope failureWire rope failure during a lifting operation drops the load, with potentially fatal consequences for everyone below.
Legal requirementLOLER 1998 requires thorough examination of lifting accessories at intervals not exceeding six months.
Early detectionRegular inspection identifies deterioration before failure, allowing replacement at a safe and planned time.
Do Don't
  • Carry out a visual pre-use inspection of wire ropes before every lift
  • Check for broken wires, corrosion, kinks, flattening, and diameter reduction
  • Measure rope diameter at multiple points to check for wear and stretch
  • Inspect terminations including ferrules, thimbles, and swaged end fittings
  • Reject and quarantine any rope showing mechanical damage or excessive wear
  • Ensure thorough examinations are completed by a competent person within LOLER intervals
  • Keep examination certificates and inspection records available on site
  • Lubricate wire ropes in accordance with manufacturer recommendations
  • Store ropes off the ground on reels or racks to prevent corrosion and damage
  • Report any defects found during inspection to the lifting supervisor immediately
  • DON'T use wire ropes that have not been thoroughly examined within the LOLER interval
  • DON'T attempt to repair broken wires, kinks, or bird-caging — reject the rope
  • DON'T drag wire ropes over sharp edges, rough surfaces, or through dirt
  • DON'T expose wire ropes to welding sparks, cutting flames, or high temperatures
  • DON'T use a rope with more than the permitted number of broken wires per lay length
  • DON'T coil wire ropes in tight loops that cause kinking or permanent deformation
  • DON'T overload wire ropes beyond their safe working load at any time
  • DON'T ignore corrosion — internal corrosion can weaken a rope that looks acceptable externally
  • DON'T use wire ropes with damaged or cracked ferrules or thimble fittings
  • DON'T store wire ropes in wet conditions or in contact with chemicals

See also: Lifting Accessories Pre-Use Checks | Lifting Operations Awareness (LOLER)

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