Common Causes Of Steel Wire Rope Failure And How To Prevent Them

By Author: Indolift
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Steel wire ropes are essential components in industries such as construction, mining, marine, oil & gas, and manufacturing. Their ability to withstand enormous loads and harsh environmental conditions makes them irreplaceable. However, even the most durable wire ropes are vulnerable to failure if not properly used, maintained, and inspected.
In this article, we explore the common causes of steel wire rope failure and provide practical, expert-backed prevention strategies to help you maximize rope life, reduce downtime, and ensure operational safety.

What is Steel Wire Rope Failure?
Steel wire rope failure refers to the point at which the rope can no longer perform its intended function due to structural degradation, breakage, or reduced strength. This can result from various mechanical, environmental, or handling issues.

Common Causes of Steel Wire Rope Failure
1. Fatigue from Repeated Bending
Wire ropes frequently bend over drums, pulleys, and sheaves, especially in cranes and elevators. This repeated flexing leads to metal fatigue, especially near the outer strands.
Signs:
...
... • Small broken wires on the outer layer.
• Abrasions or flattening at bending points.
Prevention:
• Use sheaves with the proper groove size and diameter.
• Replace sheaves with worn grooves.
• Choose ropes with fatigue-resistant construction like rotation-resistant ropes or those with compacted strands.

2. Corrosion
Corrosion occurs when ropes are exposed to moisture, chemicals, or salty environments (e.g., marine operations). It weakens internal wires, often without visible external damage.
Signs:
• Reddish or greenish powder on strands.
• Loss of metallic sheen.
• Hidden internal rust leading to unexpected breakage.
Prevention:
• Use galvanized or stainless steel wire ropes in corrosive environments.
• Regularly apply lubricants with corrosion inhibitors.
• Inspect and clean ropes frequently.
• Store ropes in dry, covered conditions.

3. Overloading
Using a wire rope beyond its rated capacity causes internal and external wire damage. Even one instance of overloading can significantly reduce its lifespan.
Signs:
• Flattened, kinked, or bird-caged sections.
• Broken strands.
• Elongation or core protrusion.
Prevention:
• Always adhere to the Working Load Limit (WLL).
• Use load monitoring devices in lifting operations.
• Train operators on load rating charts.
• Select a rope with a safety factor appropriate for dynamic loads.

4. Abrasion
Friction between the wire rope and contact surfaces can wear away the outer wires. This is especially common in sliding applications or when ropes rub against sharp edges.
Signs:
• Shiny, polished sections.
• Flattened strands.
• Strand distortion.
Prevention:
• Install proper guards and fairleads.
• Use sheaves and drums of appropriate size and smoothness.
• Apply lubrication to reduce friction.
• Use plastic-coated wire ropes in high-abrasion areas.

5. Kinking and Improper Handling
Wire ropes are sensitive to improper uncoiling or sudden jerks during installation. Kinks deform the structure and weaken the core.
Signs:
• Sharp bends or permanent deformation.
• Uneven winding on drums.
• Loss of flexibility.
Prevention:
• Use rotating turntables or reels to uncoil rope properly.
• Avoid dragging ropes over obstacles or rough surfaces.
• Train staff in correct handling and coiling techniques.

6. Lack of Lubrication
Steel wire ropes need lubrication to reduce friction between wires and strands. Without proper lubrication, ropes deteriorate quickly under stress and environmental exposure.
Signs:
• Squeaking sounds during movement.
• Dry or rusted appearance.
• Brittle wire breaks.
Prevention:
• Use compatible wire rope lubricants (penetrating and coating types).
• Schedule periodic lubrication based on usage and environment.
• Use automatic lubrication systems for continuous operations.

7. Improper Storage
Storing ropes in damp, uncovered, or chemically reactive areas can accelerate corrosion and damage the rope structure before it's even used.
Signs:
• Surface rust before deployment.
• Flattened coils or kinks.
• Mold, chemical stains, or mechanical damage.
Prevention:
• Store wire ropes in covered, dry, and ventilated areas.
• Keep ropes on reels or suspended above the ground.
• Apply protective coatings if stored for extended periods.

8. Poor Installation or Termination
Improper splicing, socketing, or end-fittings can concentrate stress at weak points and lead to failure under tension.
Signs:
• Rope slippage at terminations.
• Loosened end fittings.
• Fraying at splice points.
Prevention:
• Use certified end fittings and proper splicing methods.
• Ensure terminations match load requirements.
• Conduct pull tests after installation.
How to Prevent Steel Wire Rope Failure: Best Practices
Preventing steel wire rope failure is not just about addressing one factor—it’s about creating a culture of maintenance, training, and proper usage.
1. Regular Inspections
Inspect ropes visually and with tools (e.g., magnetic flux leakage detectors) before every use, especially in lifting and critical load applications.
Inspection checklist includes:
• Broken wires
• Rust/corrosion
• Core protrusion
• Diameter reduction
• Deformation
Follow industry standards like ISO 4309 or ASME B30.9 for wire rope inspection criteria.

2. Proper Rope Selection
Choosing the correct type of steel wire rope based on application, load, bend radius, and environment is crucial.
Factors to consider:
• Construction (e.g., 6x36, 8x19, compacted, swaged)
• Core type (FC, IWRC)
• Coating (Galvanized, PVC, stainless steel)
• Flexibility and fatigue resistance
Consult with Wire Rope Manufacturers in India for customized recommendations.
3. Operator Training
Even the best equipment fails when improperly used. Train operators in:
• Load limits
• Rigging techniques
• Rope inspection
• Handling and coiling
4. Use of Rope Accessories
Enhance performance and lifespan with:
• Thimbles
• Pulley guards
• Winch drums with proper grooves
• Tension indicators
5. Documentation and Monitoring
Maintain records of:
• Inspection logs
• Maintenance schedules
• Load history
• Environmental exposure
Use digital tools or CMMS (Computerized Maintenance Management Systems) to track rope performance and replacements.

Partner With the Right Wire Rope Company
Reliable wire rope manufacturers in India offer not just quality products but also technical support, training, and post-sales service. Look for manufacturers who:
• Provide certified and tested ropes.
• Offer application-specific advice.
• Have strong quality control and R&D practices.
Steel wire rope failure is preventable with the right knowledge, practices, and partnerships. By addressing the common causes—fatigue, corrosion, overloading, abrasion, and more—you can extend the lifespan of your ropes and improve workplace safety.
Whether you're working with cranes, elevators, marine applications, or heavy industrial equipment, prevention starts with:
• Choosing the right rope,
• Ensuring proper handling,
• Regular inspections, and
• Working with reputable Steel Wire Ropes manufacturers.