Question 1

Standard wire rope inspection requirements for 'Running Ropes' mandate replacement if there are ___ broken wires in one rope lay.

Accepted Answer

OSHA 1926.1413 requires removal if there are 6 randomly distributed broken wires in one rope lay (or 3 in one strand in one lay).

Question 2

For 'Rotation Resistant' wire rope, the replacement criterion is:

Accepted Answer

Rotation resistant rope has stricter criteria: 2 broken wires in 6 rope diameters, or 4 broken wires in 30 rope diameters.

Question 3

Wire rope must be removed from service if wear exceeds ___ of the original diameter of outside wires.

Accepted Answer

Wear of one-third (1/3) the original diameter of outside individual wires is cause for removal.

Question 4

A 'birdcage' in a wire rope is:

Accepted Answer

Birdcaging is a structural deformation where strands are forced apart, usually due to sudden release of tension or shock loading. It requires immediate replacement.

Question 5

How many broken wires are allowed at an end connection (socket) before replacement is required?

Accepted Answer

Wait, specifically: One (1) broken wire at an end connection (valley break near socket) is cause for removal or re-socketing.

Question 6

Who is qualified to inspect wire rope?

Accepted Answer

Daily (shift) inspections must be performed by a Competent Person.

Question 7

Core protrusion is:

Accepted Answer

Protrusion of the core indicates severe structural damage. The rope must be removed.

Question 8

Standing ropes (pendants) must be replaced if they have more than ___ broken wires in one rope lay.

Accepted Answer

For standing ropes (which don't move over sheaves), the limit is 3 broken wires in one lay (or 2 at end connection).

Question 9

The frequency of wire rope inspection is:

Accepted Answer

Inspections are required every shift (visual), monthly (documented), and annually (comprehensive).

Question 10

Reduction of nominal diameter of more than ___ is cause for replacement.

Accepted Answer

OSHA specifies reduction limits: e.g., 3/64 inch for diameters up to 3/4 inch. Generally around 5-10% reduction indicates core failure or excessive wear.

Question 11

If a wire rope shows evidence of heat damage (discoloration/blueing), it must be:

Accepted Answer

Heat damage destroys the lubrication and tempering of the steel wires. It must be replaced.

Question 12

What is 'Kinking'?

Accepted Answer

Kinking creates a permanent distortion in the rope structure that cannot be fixed. It is cause for removal.

Question 13

Rotation resistant rope is used primarily for:

Accepted Answer

Rotation resistant rope is designed to counteract torque so a single part line doesn't spin the load. It is delicate and requires strict inspection.

Question 14

When cutting wire rope, it should be:

Accepted Answer

Seizing prevents the strands from unlaying (unraveling) and maintains the structural integrity at the end.

Question 15

A 'Valley Break' (wire breaking at the contact point between strands) is:

Accepted Answer

Valley breaks often indicate core failure or internal corrosion. Even one valley break is often cause for immediate removal (standard varies, but usually treated very seriously).

Question 16

Lubrication of wire rope:

Accepted Answer

Field lubrication is essential to maintain rope life.

Question 17

The 'Design Factor' for running ropes on mobile cranes is typically:

Accepted Answer

For mobile crane running ropes (hoist lines), the safety factor is typically 3.5:1. (For rotation resistant, it's 5:1. For slings, 5:1).

Question 18

If a rope has 2 broken wires in 6 rope diameters (Rotation Resistant), you must:

Accepted Answer

This meets the removal criteria for rotation resistant rope (2 in 6d or 4 in 30d).

Question 19

Crushed or flattened rope sections are caused by:

Accepted Answer

Multi-layer spooling where the rope crosses over or dives into lower layers causes crushing. Severe crushing requires replacement.

Question 20

Corroded (pitted) wire rope:

Accepted Answer

Severe corrosion (pitting) weakens the steel and prevents internal movement. It is removal criteria.

Question 21

The minimum number of full wraps to remain on the drum at the lowest hook position is:

Accepted Answer

OSHA/ASME require at least 2 full wraps of rope to remain on the drum to ensure the rope does not pull out of the anchorage.

Question 22

Which part of the rope is most subject to wear?

Accepted Answer

Bending over sheaves causes fatigue and wear. These sections need closest inspection.

Question 23

Measuring rope diameter should be done:

Accepted Answer

Diameter is measured across the crowns (the widest dimension) using calipers.

Question 24

High stranding (unlaying) allows:

Accepted Answer

Strand separation allows contaminants in and indicates structural failure.

Question 25

Internal corrosion is often indicated by:

Accepted Answer

Rouge is rust powder grinding out from the core, indicating severe internal corrosion.

Question 26

A 'Lay Length' is:

Accepted Answer

Inspection criteria are based on 'one rope lay' length.

Question 27

If you install a new rope, you should:

Accepted Answer

Break-in allows the strands to seat properly.

Question 28

What type of core is most common in crane hoist ropes?

Accepted Answer

IWRC provides higher strength and resistance to crushing on the drum.

Question 29

Electric contact (arc strike) on a wire rope:

Accepted Answer

Arc strikes embrittle the wires, making them prone to snapping. The rope must be replaced.

Question 30

The Monthly inspection of wire rope must be:

Accepted Answer

OSHA requires a documented monthly inspection kept on file for at least 3 months.

Wire Rope Inspection Practice Questions

More NCCCO Crane Operator Exam Topics