A running wire rope must come out of service at six randomly distributed broken wires in one rope lay, according to Legal Information Institute.
Key takeaways for when a crane wire rope must come out of service
- Retire the running rope when you find six randomly distributed broken wires in one rope lay, according to Legal Information Institute. The same federal page sets the limit at three broken wires in one strand within a single rope lay. A rope lay is the length along the rope where one strand completes a full revolution.
- California uses the same running-rope threshold. Its Title 8 inspection rule states the limit is six randomly distributed broken wires in one rope lay, or three broken wires in one strand in one lay, according to California Department of Industrial Relations.
- For standing ropes, the federal standard is stricter near the connections. The rule requires removal when more than two broken wires appear in one rope lay beyond the end connections, according to Legal Information Institute. At the end connection itself, the limit drops to more than one broken wire in a rope lay.
When the rope comes out of service
The federal rule for running wire ropes sets a specific broken-wire count that triggers retirement. Under this standard, a rope is removed from service when it has six randomly distributed broken wires within a single rope lay. The same rule also requires removal if there are three broken wires in one strand within that same rope lay. This definition applies specifically to running wire ropes, distinguishing them from other rope types that may have different thresholds. The count is not a general limit for all rope configurations but a precise trigger for this category. When you inspect the hoist rope before the next lift, you are checking for these specific distribution patterns. If you find six broken wires scattered randomly across one lay, the rope must be retired. Alternatively, if you find three broken wires concentrated in a single strand within one lay, the rope also must be retired. The definition of a rope lay is critical because it establishes the measurement window for these counts. Within that specific length, you count the broken wires. The randomness of the six-wire count matters; they are not required to be in one strand, but they must be within the same lay. The three-wire count is more specific, requiring those breaks to be in one strand. Both conditions result in the rope coming out of service. This is a hard limit for running ropes under the cited federal text. You do not average these counts over multiple lays; the trigger is based on a single lay. If the rope meets either condition, it is out of service. The source names this as a rule for running wire ropes, so you apply it to the hoist line that moves the load. You do not apply this specific six-wire random count to standing ropes, which have their own limits. You do not apply it to rotation-resistant ropes, which also have distinct counts.
The federal counts for running rope, rotation-resistant rope, and standing rope
The federal standard for wire rope inspection sets specific broken-wire limits based on the rope's function and construction. For rotation-resistant ropes, the rule specifies that the rope must be removed from service if there are two randomly distributed broken wires in six rope diameters or four randomly distributed broken wires in 30 rope diameters, according to Legal Information Institute. This count applies specifically to the rotation-resistant type and is distinct from the counts used for other rope configurations.
For pendants or standing wire ropes, the federal rule requires removal if there are more than two broken wires in one rope lay located in rope beyond end connections, or more than one broken wire in a rope lay located at an end connection, according to Legal Information Institute. These standing rope limits are separate from the running rope counts and address the specific stress points at the end connections. The rule also states that joining lengths of wire rope by splicing is prohibited, according to Legal Information Institute. This prohibition applies to the method of joining and is part of the same federal inspection standard.
When inspecting a crane's wire rope, you must distinguish between these rope types. The rotation-resistant rope uses the two-wire or four-wire counts depending on the diameter span measured. The standing rope uses the two-wire limit for the body and the one-wire limit at the end connections. Do not apply the running rope count to a standing rope, as the federal rule defines them separately. The splicing prohibition is a separate requirement that applies regardless of the broken-wire count.
Check the rope type before applying the broken-wire count. If the rope is rotation-resistant, measure the broken wires over the specified diameter spans. If the rope is a pendant or standing rope, check the body and the end connections separately. Write the rope type and the broken-wire count on your site record, beside the Construction Daily Log Checklist for Supervisors. The federal rule does not provide a single count for all rope types; it provides specific counts for each named type. Use the count that matches the rope you are inspecting.
California's 6-wire line and the inspection record
California sets specific broken-wire thresholds for crane ropes that mirror the federal counts but operate under the California Code of Regulations, Title 8, Section 5031. Inspection. For running ropes, the limit is 6 randomly distributed broken wires in one rope lay, or 3 broken wires in one strand in one lay, according to California Department of Industrial Relations. This distinction matters because a cluster of three broken wires in a single strand triggers retirement even if the total count across the lay is lower. When you inspect the hoist rope, look for both the total distributed count and any localized strand damage.
Standing ropes have a different threshold. The rule states that in standing ropes, more than 2 broken wires in one lay in sections beyond end connections or more than one broken wire at an end connection requires the rope to come out of service, according to California Department of Industrial Relations.
Washington's visible broken-wire lines
WAC 296-155-53404 sets specific visible broken-wire limits for different crane rope types in Washington. For running wire ropes, the rule states that six randomly distributed broken wires in one rope lay, or three broken wires in one strand in one rope lay, require the rope to come out of service, according to Washington State Legislature. The page defines a rope lay as the length along the rope in which one strand makes a complete revolution around the rope, according to Washington State Legislature. When inspecting a standard hoist rope, count the broken wires within that single revolution length to determine if the limit is reached.
Rotation-resistant ropes use different measurement standards. The rule specifies that two randomly distributed broken wires in six rope diameters, or four randomly distributed broken wires in 30 rope diameters, trigger removal from service, according to Washington State Legislature. These counts are distinct from the rope lay counts used for standard running ropes. If your crane uses rotation-resistant wire, measure the distance in rope diameters rather than relying on the single revolution definition.
Standing wire ropes, also called pendants, have their own thresholds. The rule states that more than two broken wires in one rope lay located in rope beyond end connections, and/or more than one broken wire at an end connection, requires the rope to be retired, according to Washington State Legislature. This means the count at the connection point is stricter than the count in the body of the rope.
The Washington rule also includes a general hazard provision. It states that in making this determination, more than one broken wire in any one rope lay must be considered a hazard, according to Washington State Legislature.
Keep the Washington counts separate from federal or California numbers. Do not treat one publisher's number as another publisher's number. Use the Washington State Legislature page for Washington-specific compliance.
A filled reference table of the rope rules by publisher
The table below compares the broken-wire limits for running and standing wire ropes across the three publishers.
| Publisher | Running Rope Limit | Standing Rope Limit | Source Page |
|---|---|---|---|
| Legal Information Institute | Six randomly distributed broken wires in one rope lay or three broken wires in one strand in one rope lay | 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. | 29 CFR § 1926.1413 - inspection. |
| California Department of Industrial Relations | 6 randomly distributed broken wires in one rope lay, or 3 broken wires in one strand in one lay | In standing ropes, more than 2 broken wires in one lay in sections beyond end connections or more than one broken wire at an end connection. | California Code of Regulations, Title 8, Section 5031. Inspection. |
| Washington State Legislature | Six randomly distributed broken wires in one rope lay, or three broken wires in one strand in one rope lay | More than two broken wires in one rope lay located in rope beyond end connections, and/or more than one broken wire at an end connection | WAC 296-155-53404: |
The Legal Information Institute defines a rope lay as the length along the rope in which one strand makes a complete revolution around the rope, according to Legal Information Institute. The California Department of Industrial Relations lists the same 6-wire and 3-wire thresholds for running ropes on its inspection page, according to California Department of Industrial Relations. The Washington State Legislature specifies visibly broken wires in running wire ropes using the identical 6-wire and 3-wire counts, according to Washington State Legislature.
GovRegs repeats the federal rope page and is not a state rule, so it does not appear as a separate row here. Use this table to verify that the rope on your crane matches the running-rope definition before deciding whether it stays in service.
Today's rope check
The federal rule for running wire ropes requires 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, according to Legal Information Institute. Record the number of broken wires you see in a single lay. If you find three broken wires in one strand within that same lay, note that specific location. Keep this entry separate from any standing rope counts you may check elsewhere. The goal is a clear, written record of what you observed on the running rope today. Do not rely on memory; the written count is the site record. If the count reaches the limit, the rope comes out of service.
Illustrative example of one lay count
Picture one running hoist rope before a lift. In a single rope lay you find six broken wires spread across several strands. In that same lay, one strand holds three broken wires, which is the strand line for a running rope. A pendant beyond the end connection shows two broken wires in one lay. Two is not more than two, so that standing-rope line is not met. At the end connection, one broken wire is not more than one. On a rotation-resistant rope, two broken wires inside six rope diameters meet the removal line. No length is joined by splicing.
Before the next lift, count the broken wires the page names and write the count and the page on today's site record. Pair that note with Log lifting sling inspections: 6 checks before the lift.
FAQ about retiring a hoist rope
What does 6 broken wires refer to?
The count of six broken wires applies specifically to running wire ropes. It triggers retirement when six randomly distributed broken wires appear in one rope lay, or three broken wires appear in one strand within one rope lay. A rope lay is defined as the length along the rope in which one strand makes a complete revolution around the rope, according to Legal Information Institute.
What is the standing-rope count?
For pendants or standing wire ropes, the limit is more than two broken wires in one rope lay located in rope beyond end connections. Additionally, more than one broken wire in a rope lay located at an end connection requires removal from service. These specific thresholds apply to standing ropes rather than running ropes, according to Legal Information Institute.
What does rotation-resistant rope use?
Rotation-resistant ropes use a different broken-wire limit based on rope diameters. The rule specifies two randomly distributed broken wires in six rope diameters or four randomly distributed broken wires in 30 rope diameters. This standard differs from the rope lay counts used for standard running ropes, according to Legal Information Institute.
What does California say to keep on file?
California requires that inspection records be maintained on file for a minimum of 48 months by the employer. This record-keeping rule applies to the inspection documentation for wire ropes. The 48-month minimum ensures that historical inspection data remains available for review, according to California Department of Industrial Relations.
What to write before the lift?
Write the broken-wire count and the specific page reference on today's site record before the next lift. Documenting the count and the source page creates a clear trail of your inspection decision. This practice supports the requirement to maintain inspection records on file for the required period, as noted by California Department of Industrial Relations.