Wire Rope Inspection and Replacement Flashcards
6 cards from real NCCCO practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.
Read the first 6 Wire Rope Inspection and Replacement flashcards as text
When inspecting wire rope on a crane, what are 'valley breaks' and why are they particularly serious?
Answer: Wire breaks occurring in the valleys between strands — they are hidden from easy view and indicate advanced fatigue requiring immediate removal from service
Valley breaks occur in the contact zones between strands (valleys), hidden from easy view. They indicate internal fatigue and typically occur before crown breaks, making them a critical condition requiring removal from service.
Wire rope has a measured diameter of 0.94 inches but its nominal (rated) diameter is 1 inch. Should this rope be removed from service?
Answer: Yes — a reduction greater than 1/16 inch below nominal for 7/8-inch to 1-1/8-inch ropes requires removal per ASME B30.5
ASME B30.5 requires wire rope removal when the diameter is reduced more than 1/16 inch below nominal for ropes in the 7/8-inch to 1-1/8-inch range. A 0.06-inch reduction on a 1-inch rope meets this removal threshold.
What does 'bird-caging' in a wire rope indicate, and what action is required?
Answer: The outer strands have expanded outward from the core due to shock loading or severe reverse bending — the rope must be removed from service immediately
Bird-caging occurs when outer wire strands splay outward from the rope's core, resembling a bird cage. It results from sudden shock loading, kinking, or running over a too-small sheave. The rope has lost its structural integrity and must be removed from service.
Which end termination is typically used for permanent attachment of wire rope to a crane drum or dead end anchor to achieve full rated breaking strength?
Answer: Swaged (pressed) or spelter socket terminations, which achieve 100% of the wire rope's rated breaking strength
Swaged sockets and spelter (zinc-poured) sockets achieve 100% efficiency — the full rated breaking strength of the wire rope — making them the preferred permanent terminations for crane applications where safety is critical.
When installing wire rope clips (clamps) on a wire rope, what is the correct clip orientation rule?
Answer: Never saddle a dead horse — the clip saddle bears on the live (loaded) rope end and the U-bolt bears on the dead (short) end
The mnemonic 'never saddle a dead horse' means the saddle (flat bearing surface) of the clip always bears on the live (load-carrying) rope end, never on the dead end. Reversing this reduces clip efficiency by up to 40%.
How should wire rope be stored on a job site to prevent damage before being installed on a crane?
Answer: On reels or coils in a dry, covered area off the ground, away from chemicals and extreme heat, with end caps to prevent unraveling
Wire rope should be stored on reels or coils in a clean, dry area elevated off the ground to prevent corrosion, contamination, and mechanical damage. End caps prevent strand unraveling.