Wire rope is a type of cable made up of several strands of metal wire twisted together to form a helix. It's commonly used in various applications like lifting, rigging, and towing due to its strength and flexibility.

Wire rope is classified based on its construction, materials, and usage. Common classifications include general engineering ropes, rotation-resistant ropes, structural application ropes, compacted ropes, galvanized wire ropes etc.

Several factors influence wire rope selection, including:

• Load Capacity

• Environmental conditions (temperature, corrosion)

• Flexibility and bending characteristics

• Abrasion resistance

• Fatigue resistance

• Maintenance requirements

The lifespan of wire rope depends on various factors such as usage, environmental conditions, maintenance, and load capacity. Regular inspection and proper lubrication can help extend its lifespan.

Regular visual inspections should be conducted for signs of wear, broken wires, corrosion, and deformation. In addition, non-destructive testing methods like magnetic rope testing (MRT) or Radiographic testing can be used for thorough examination.

Proper lubrication is essential to reduce friction, prevent corrosion, and prolong the life of wire rope. Additionally, storing wire rope away from moisture and chemicals, avoiding overloading, and conducting regular inspections are crucial maintenance practices.

Wire rope can fail due to various reasons including overloading, fatigue from repetitive stress, corrosion, abrasion, improper installation, and lack of maintenance. Identifying and addressing these factors promptly can prevent accidents and extend the lifespan of wire rope.

Minor damage to wire rope like broken wires can often be repaired by splicing or cutting out the damaged section and reconnecting the ends. However, severe damage or wear may require replacing the entire length of wire rope for safety reasons. Always consult with a qualified professional for repairs.

Always follow manufacturer guidelines and industry standards for handling, installation, and usage of wire rope. Use appropriate personal protective equipment (PPE), inspect equipment regularly, avoid overloading, and seek professional assistance when in doubt to ensure safety.

Selecting a proper wire rope isn’t easy. These are a few important factors to keep in mind:

1. UNDERSTAND WIRE ROPE CONSTRUCTION AND CORE.

2. KNOW YOUR WIRE ROPE LOAD LIMITS.

3. KNOW YOUR ROPE’S TENSILE STRENGTH.

1. SINGLE LAYER- a) This is a basic strand construction has wires of the same size wound around a center wire.

2. SEALE (S) - a) Large outer wires with the same number of smaller inner wires around a core wire. b) Provides excellent abrasion resistance. c) When used with an IWRC, it offers excellent crush resistance over drums.

3. FILLER (F) - a) In this design, in each valley between two layers a small wire is filled. b) Small wires fill spaces between large wires to produce crush resistance and a good balance of strength, flexibility, and resistance to abrasion.

4. WARRINGTON (W) - a) In this design, a layer of pairs of wires (one large and one small) is laid over an inner layer of wires. b) The outer layer of alternately large and small wires provides good flexibility and strength but low abrasion and crush resistance.

1) Decrease in Diameter 

2) Corrosion

3) Waviness 

4) Basket or lantern deformation or Bird caging

5) Core or Strand Protrusion

6) Wire Protrusion

7) Local increase in Rope Diameter

8) Broken Wires: - A) Crown Wire Breaks  B) Valley Wire Breaks

9) Kinking