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Subchapter 4. Construction Safety Orders
Article 15. Cranes and Derricks in Construction

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§1613.10. Inspections - Wire Rope.

(a) Shift inspection.

(1) A qualified person shall begin a visual inspection prior to each shift the equipment is used, which shall be completed before or during that shift.

The inspection shall consist of observation of wire ropes (running and standing) that are likely to be in use during the shift for apparent deficiencies, including those listed in subsection (a)(2). Untwisting (opening) of wire rope or booming down is not required as part of this inspection.

(2) Apparent deficiencies.

(A) Category I. Apparent deficiencies in this category include the following:

1. Significant distortion of the wire rope structure such as kinking, crushing, unstranding, birdcaging, signs of core failure or steel core protrusion between the outer strands.

2. Significant corrosion.

3. Electric arc damage (from a source other than power lines) or heat damage.

4. Improperly applied end connections.

5. Significantly corroded, cracked, bent, or worn end connections (such as from severe service).

(B) Category II. Apparent deficiencies in this category are:

1. Visible broken wires, as follows:

a. In running wire ropes: Six randomly distributed broken wires in one rope lay or three broken wires in one strand in one rope lay, where a rope lay is the length along the rope in which one strand makes a complete revolution around the rope.

b. In rotation resistant ropes: Two randomly distributed broken wires in six rope diameters or four randomly distributed broken wires in 30 rope diameters.

c. In pendants or standing wire ropes: More than two broken wires in one rope lay located in rope beyond end connections and/or more than one broken wire in a rope lay located at an end connection.

2. A diameter reduction of more than 5% from nominal diameter.

(C) Category III. Apparent deficiencies in this category include the following:

1. In rotation resistant wire rope, core protrusion or other distortion indicating core failure.

2. Prior electrical contact with a power line.

3. A broken strand.

(3) Critical review items. The qualified person shall give particular attention to all of the following:

A. Rotation resistant wire rope in use.

B. Wire rope being used for boom hoists and luffing hoists, particularly at reverse bends.

C. Wire rope at flange points, crossover points and repetitive pickup points on drums.

D. Wire rope at or near terminal ends.

E. Wire rope in contact with saddles, equalizer sheaves or other sheaves where rope travel is limited.

(4) Removal from service.

(A) If a deficiency in Category I [see subsection (a)(2)(A)] is identified, an immediate determination shall be made by the qualified person as to whether the deficiency constitutes a safety hazard. If the deficiency is determined to constitute a safety hazard, operations involving use of the wire rope in question shall be prohibited until:

1. The wire rope is replaced, or

2. If the deficiency is localized, the problem is corrected by severing the wire rope in two; the undamaged portion may continue to be used. Joining lengths of wire rope by splicing is prohibited. If a rope is shortened under this section, the employer shall ensure that the drum will still have two wraps of wire when the load and/or boom is in its lowest position.

(B) If a deficiency in Category II [see subsection (a)(2)(B)] is identified, operations involving use of the wire rope in question shall be prohibited until:

1. The wire rope is replaced, or

2. If the deficiency is localized, the problem is corrected by severing the wire rope in two; the undamaged portion may continue to be used. Joining lengths of wire rope by splicing is prohibited. If a rope is shortened under this section, the employer shall ensure that the drum will still have two wraps of wire when the load and/or boom is in its lowest position.

(C) If a deficiency in Category III is identified, operations involving use of the wire rope in question shall be prohibited until:

1. The wire rope is replaced, or

2. If the deficiency (other than power line contact) is localized, the problem is corrected by severing the wire rope in two; the undamaged portion may continue to be used. Joining lengths of wire rope by splicing is prohibited. Repair of wire rope that contacted an energized power line is also prohibited. If a rope is shortened under this section, the employer shall ensure that the drum will still have two wraps of wire when the load and/or boom is in its lowest position.

(D) Where a wire rope is required to be removed from service under this section, either the equipment (as a whole) or the hoist with that wire rope shall be tagged-out, in accordance with Section 1616.1(g)(1), until the wire rope is repaired or replaced.

(b) Monthly inspection.

(1) Each month an inspection shall be conducted in accordance with subsection (a) (Shift Inspection).

(2) The inspection shall include any deficiencies that the qualified person who conducts the annual inspection determines under subsection (c)(3)(B) shall be monitored.

(3) Wire ropes on equipment shall not be used until an inspection under this section demonstrates that no corrective action under subsection (a)(4) is required.

(4) The inspection shall be documented according to Section 1613.5(a)(3) (monthly inspection documentation).

(c) Annual/comprehensive.

(1) At least every 12 months, wire ropes in use on equipment shall be inspected by a qualified person in accordance with subsection (a) (Shift Inspection).

(2) In addition, at least every 12 months, the wire ropes in use on equipment shall be inspected by a qualified person, as follows:

(A) The inspection shall be for deficiencies of the types listed in subsection (a)(2).

(B) The inspection shall be complete and thorough, covering the surface of the entire length of the wire ropes, with particular attention given to all of the following:

1. Critical review items listed in subsection (a)(3).

2. Those sections that are normally hidden during shift and monthly inspections.

3. Wire rope subject to reverse bends.

4. Wire rope passing over sheaves.

Exception: In the event an inspection under subsection (c)(2) is not feasible due to existing set-up and configuration of the equipment (such as where an assist crane is needed) or due to site conditions (such as a dense urban setting), such inspections shall be conducted as soon as it becomes feasible, but no longer than an additional 6 months for running ropes and, for standing ropes, at the time of disassembly.

(3) If a deficiency is identified, an immediate determination shall be made by the qualified person as to whether the deficiency constitutes a safety hazard.

(A) If the deficiency is determined to constitute a safety hazard, operations involving use of the wire rope in question shall be prohibited until:

1. The wire rope is replaced, or

2. If the deficiency is localized, the problem is corrected by severing the wire rope in two; the undamaged portion may continue to be used. Joining lengths of wire rope by splicing is prohibited. If a rope is shortened under this section, the employer shall ensure that the drum will still have two wraps of wire when the load and/or boom is in its lowest position.

(B) If the qualified person determines that, though not presently a safety hazard, the deficiency needs to be monitored, the employer shall ensure that the deficiency is checked in the periodic inspections.

(4) The inspection shall be documented according to Section 1613.6(g) Inspections - Annual/Comprehensive.

(d) Rope lubricants that are of the type that hinder inspection shall not be used.

(e) All documents produced under this section shall be available, during the applicable document retention period, to all persons who conduct inspections under this section.

Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.

HISTORY

1. New section filed 7-7-2011; operative 7-7-2011. Exempt from OAL review pursuant to Labor Code section 142.3(a)(3) (Register 2011, No. 27).

2. Repealer of subsection (a)(4)(B)1. and subsection renumbering filed 10-2-2012; operative 11-1-2012 (Register 2012, No. 40).


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