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Subchapter 7. General Industry Safety Orders
Group 13. Cranes and Other Hoisting Equipment
Article 100. Inspection and Maintenance
§5036. Inspection -- Wire Rope (Additional Requirements for Cranes and Derricks in Construction).
(a) Apparent deficiencies.
(1) Category I. Apparent deficiencies in this category include the following:
(A) 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.
(B) Significant corrosion.
(C) Electric arc damage (from a source other than power lines) or heat damage.
(D) Improperly applied end connections.
(E) Significantly corroded, cracked, bent, or worn end connections (such as from severe service).
(2) Category II. Apparent deficiencies in this category are:
(A) Visible broken wires, as follows:
1. In running wire ropes: Six randomly distributed broken wires in one rope lay or three broken wires in one strand in one rope lay.
2. In rotation resistant ropes: Two randomly distributed broken wires in six rope diameters or four randomly distributed broken wires in 30 rope diameters.
3. 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.
(B) A diameter reduction of more than 5% from nominal diameter.
(3) Category III. Apparent deficiencies in this category include the following:
(A) In rotation resistant wire rope, core protrusion or other distortion indicating core failure.
(B) Prior electrical contact with a power line.
(C) A broken strand.
(b) Critical review items. The inspector shall give particular attention to all of the following:
(1) Rotation resistant wire rope in use.
(2) Wire rope being used for boom hoists and luffing hoists, particularly at reverse bends.
(3) Wire rope at flange points, crossover points and repetitive pickup points on drums.
(4) Wire rope at or near terminal ends.
(5) Wire rope in contact with saddles, equalizer sheaves or other sheaves where rope travel is limited.
(c) Removal from service.
(1) If a deficiency in Category I is identified, operations involving use of the wire rope in question shall be prohibited until:
(A) The wire rope is replaced, or
(B) If the deficiency is localized, the problem is corrected by severing the wire rope in two; the undamaged portion may continue to be used.
(2) If a deficiency in Category II is identified, operations involving use of the wire rope in question shall be prohibited until:
(A) The employer complies with the wire rope manufacturer's established criterion for removal from service or a different criterion that the wire rope manufacturer has approved in writing for that specific wire rope,
(B) The wire rope is replaced, or
(C) If the deficiency is localized, the problem is corrected by severing the wire rope in two; the undamaged portion may continue to be used.
(3) If a deficiency in Category III is identified, operations involving use of the wire rope in question shall be prohibited until:
(A) The wire rope is replaced, or
(B) 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. Repair of wire rope that contacted an energized power line is prohibited.
(4) 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 subsection 5008.1(e)(1), until the wire rope is repaired or replaced.
(d) Periodic inspection.
(1) Periodic inspections shall be conducted in accordance with Section 5031(c).
(2) The inspection shall include any deficiencies that the certificating agency that conducts the annual inspection determines under subsection (e)(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 (c) is required.
(4) The inspection shall be documented according to subsection 5031(c)(3)(C).
(1) At least every 12 months, wire ropes in use on equipment shall be inspected by a qualified person as described in Section 5021 and in accordance with subsection 5031(c).
(2) In addition, the wire ropes shall be inspected as follows:
(A) The inspection shall be for deficiencies of the types listed in subsection 5036(a).
(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 (b).
2. Those sections that are normally hidden during shift and periodic inspections.
3. Wire rope subject to reverse bends.
4. Wire rope passing over sheaves.
Exception: In the event an inspection under subsection (e)(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 certificating agency 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.
(B) If the certificating agency 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 subsection 5031(d)(5) (documentation of annual/comprehensive inspection).
(f) Joining lengths of wire rope by splicing is prohibited. If a rope is shortened by severing the wire rope in two, 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.
(g) Rope lubricants that are of the type that hinder inspection shall not be used.
(h) All documents produced under this section shall be available, during the applicable document retention period, to all persons who conduct inspections under this section.
1. New section filed 7-26-2022; operative 7-26-2022 pursuant to Government Code section 11343.4(b)(3) (Register 2022, No. 30). Filing deadline specified in Government Code section 11349.3(a) extended 60 calendar days pursuant to Executive Order N-40-20 and an additional 60 calendar days pursuant to Executive Order N-71-20.