At what percentage of diameter wear should the lifting wire rope be replaced?
4 Answers
When the outer wire wear reaches 40% of its diameter, the wire rope should be scrapped. When the wire rope diameter decreases by 7% or more relative to the nominal diameter, even if no broken wires are found, the wire rope should also be scrapped. Internal wear and dents: This situation is caused by friction between the individual strands and wires inside the rope, especially when the wire rope is subjected to bending. External wear: Incorrect lubrication as well as the presence of dust and sand particles will accelerate wear. The wear on the surface of the outer strand wires of the wire rope is caused by frictional contact with the grooves of pulleys and drums under pressure.
I've worked on construction sites for over 20 years, specializing in equipment maintenance, and have seen plenty of hazards caused by wire rope wear. When the diameter wear of a lifting wire rope reaches 10% of its original diameter, it must be replaced, as this is the minimum requirement of industry safety standards. Wear significantly reduces the rope's strength, making it prone to breakage during lifting or elevator operation, which can lead to personal injury or equipment damage. I teach workers to use calipers to regularly measure the original diameter and current value, and to immediately stop using and replace the rope once the reduction exceeds 10%. Don't underestimate this wear—it accumulates and poses significant risks. For example, if the diameter decreases from 10 mm to 9 mm, it's time to replace it. Safety comes first, and regular maintenance is key. I recommend weekly inspections to ensure everyone can work with peace of mind.
As a warehouse operator who frequently operates forklifts, I deal with wire ropes daily, and checking for wear is part of my routine. Experience tells me that when wear reaches 10%, it's time to replace the rope. For example, if the original diameter is 12mm, a drop below 10.8mm should raise an alert. I use a simple vernier caliper for measurement and regularly check for fraying or deformation. Once, I overlooked minor wear, which nearly caused an accident. Remember to replace ropes promptly to avoid injuries or work delays due to breakage. I make it a habit to inspect them at the end of each month—just a quick diameter measurement, and if it exceeds the limit, I replace the rope. It’s hassle-free and ensures safety.
The wear of the lifting wire rope will affect its strength and service life. When the diameter wear reaches 10% of the original diameter, the rope must be replaced. Here's why: wear reduces the metal cross-section, decreasing the load-bearing capacity by more than 30%, significantly increasing the risk of sudden breakage. This is commonly seen in elevator or crane ropes, and potential accidents are very dangerous. It is recommended to use high-precision tools such as calipers to measure and compare the original diameter with the current value, and take immediate action if the limit is exceeded. Replace the rope promptly, don't wait for the hazard to grow.
