LFT/Equipment/TBT-LFT-034
Wire Rope Inspection and Rejection Criteria
Lifting Operations › Equipment › Wire Rope Inspection and Rejection Criteria
Toolbox Talk
Wire Rope Inspection and Rejection Criteria
Wire ropes are used as crane hoist ropes, slings, and guy wires on construction sites. They deteriorate through wear, corrosion, fatigue, and damage, and a failed wire rope can drop a load without warning. Knowing how to inspect a wire rope and when to reject it is essential for everyone involved in lifting operations. This talk covers the inspection method and the rejection criteria every operative must know.
Key Hazards
Dropped loads from wire rope failure due to undetected wear or corrosion
Sudden strand breakage from fatigue cracking in high-cycle applications
Reduced capacity from internal corrosion not visible on the outer surface
Rope damage from sharp edges, kinks, or incorrect drum winding
Control Measures
- Inspect wire ropes visually before each use along their full working length for visible defects.
- Check for broken wires — reject if the number exceeds the criteria in BS ISO 4309 for the rope type.
- Look for flattening, kinking, birdcaging, or core protrusion along the rope length.
- Check for external corrosion, pitting, and discolouration indicating moisture attack.
- Measure rope diameter and reject if it has reduced by more than the allowable percentage for the type.
- Inspect the termination fittings including ferrules, thimbles, and swaged ends for cracks and deformation.
- Reject any wire rope showing signs of heat damage, torch burns, or electrical arcing.
- Ensure wire ropes are lubricated as recommended by the manufacturer to prevent internal corrosion.
- Record all inspection findings and rejections in the lifting equipment register for the project.
Remember
- Inspect wire ropes visually along their full working length before every use on site
- Reject ropes with broken wires exceeding the criteria specified in BS ISO 4309
- Look for flattening, kinking, birdcaging, or core protrusion as signs of serious damage
- Measure rope diameter and reject if reduction exceeds the allowable percentage for the type
- Reject any rope showing heat damage, torch burns, or signs of electrical arcing contact
- Record all inspections and rejections in the lifting equipment register for full traceability
Applicable Legislation: LOLER 1998 · BS ISO 4309 (Wire Rope Inspection and Discard) · PUWER 1998 · Health and Safety at Work etc. Act 1974
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