Wire rope splicing requirements

An eye splice in any wire rope must have at least three tucks using a whole strand and two tucks with one-half of the wires cut out of each strand. This is the minimum stated requirement in 1919.24(a).

• The three full-strand tucks restore most of the rope's strength and stability.
• The two half-wire tucks require cutting out half the wires in each strand for the last two tucks, as described in the section.

Cite: 1919.24(a).

Yes — you may use another form of splice or connection if you can show it is at least as efficient and it is not prohibited by Part 1918. The standard explicitly allows alternatives when equivalency can be demonstrated in 1919.24(a).

• To rely on an alternative you should document how the alternative matches or exceeds the strength and safety of the required splice.
• Also confirm the alternative is permitted under Part 1918, since 1919.24(a) excludes methods prohibited by that part.

Cite: 1919.24(a) and 1918.

A wire rope used for hoisting or lowering, guying derricks, or as a topping lift, preventer, or pendant must be one continuous piece without knots or splices, except for eye splices at rope ends. This is required by 1919.24(b).

• The only exception allowed in that list is an eye splice made in the ends of the wire rope.
• Avoid intermediate splices or knots in any rope that is used for those critical lifting or guying functions.

Cite: 1919.24(b).

No — eyes in the ends of wire rope cargo falls must not be formed by knots. 1919.24(c) explicitly prohibits forming eyes by knots for cargo falls.

• Knots significantly reduce the strength of wire rope and are not acceptable for forming eyes used in cargo falls.

Cite: 1919.24(c).

No — in single-part falls, eyes must not be formed by wire rope clips. 1919.24(c) forbids the use of wire rope clips to form eyes in single part falls.

• For multi-part falls the section does not explicitly ban clips, but you should follow manufacturer recommendations and accepted safe practice for multi-part assemblies.
• When in doubt, use a properly made eye splice or an approved fitting that maintains rope strength.

Cite: 1919.24(c).

The ends of falls must be secured to winch drums by clamps, U-bolts, shackles, or another method that is equally strong; fiber rope fastenings are not permitted. This requirement appears in 1919.24(d).

• Use metal clamps, U-bolts, shackles, or engineering-approved mechanical attachments sized for the rope's load.
• Do not use knots or fiber rope fastenings on the metal wire rope ends attached to winch drums.

Cite: 1919.24(d).

No — fiber rope fastenings must not be used to secure the ends of wire rope falls to winch drums. 1919.24(d) explicitly prohibits fiber rope fastenings.

• Use metal clamps, U-bolts, shackles, or an equally strong mechanical method instead.

Cite: 1919.24(d).

A wire rope must not be used for cargo gear if, in any length equal to eight rope diameters, the total number of visible broken wires exceeds 10 percent of the total wires in that length, or if the rope shows other signs of excessive wear, corrosion, or defect. This rule is stated in 1919.24(e).

• Check any 8-diameter length (see next question for how to measure) and count visible broken wires; if broken wires >10% of the rope's wires in that segment, remove the rope from service.
• Also remove rope showing severe wear, corrosion, kinking, crushing, or other structural defects.

Cite: 1919.24(e).

Measure eight diameters by taking the rope's nominal diameter and multiplying by eight; the inspection segment is that length along the rope. 1919.24(e) uses this measurement to define the area over which broken wires are counted.

• Example: for 1-inch diameter rope, inspect any 8-inch length (1 in × 8 = 8 in).
• Slide that 8-diameter measuring length along the rope to check all sections for broken wires and wear.

Cite: 1919.24(e).

Inspectors should pay particular attention to sections adjacent to terminal connections, areas exposed to abnormal wear, and sections that are not normally exposed for examination. 1919.24(e) identifies these as critical areas.

• Terminal connections (thimbles, swages, fittings) often conceal damaged or broken wires near the rope end.
• Areas that run over drums, sheaves, or sharp edges and spots normally hidden by fittings deserve closer inspection.

Cite: 1919.24(e).

No — except for eye splices at the ends, ropes used for hoisting or lowering, guying derricks, or as topping lifts, preventers, or pendants must be one continuous piece without intermediate splices. This requirement is in 1919.24(b), while 1919.24(a) covers eye splice construction.

• Middle splices in such critical lines are not allowed unless the line is not performing those listed functions or an allowed exception applies.

Cite: 1919.24(b) and 1919.24(a).

The rule in 1919.24(c) specifically prohibits forming eyes by wire rope clips for single-part falls; it does not explicitly forbid clips for multi-part falls. Therefore, for multi-part falls you should follow manufacturer guidance and accepted safe practice, and avoid clips if they would reduce safety or rope strength.

• Even where clips may be common (multi-part arrangements), ensure the chosen method is secure and does not compromise load capacity.
• When in doubt, use properly made eye splices or approved end fittings and document equivalency.

Cite: 1919.24(c).

Acceptable methods listed in 1919.24(d) include clamps, U-bolts, shackles, or another method of equal strength.

• Clamps: properly sized wire rope clips or pinch clamps designed for the rope size and load.
• U-bolts: sized and torqued per manufacturer instructions.
• Shackles or other mechanical terminations rated for the load.

Cite: 1919.24(d).

If you find broken wires exceeding 10 percent in any length of eight diameters, you must take that rope out of service for cargo gear. 1919.24(e) states this as a disqualifying condition.

• Tag or remove the rope from service immediately and replace it or have it inspected and repaired per manufacturer's or qualified person's procedures.
• Record the condition and corrective action as part of your inspection and maintenance records.

Cite: 1919.24(e).

The employer or the party using the alternative splice must be able to demonstrate that the alternative is at least as efficient as the required splice; 1919.24(a) permits alternatives only when their efficiency can be shown.

• Keep documentation such as engineering calculations, manufacturer test data, or third-party test reports that prove equivalency.
• Also ensure the alternative is not prohibited by Part 1918.

Cite: 1919.24(a) and 1918.

Beyond broken wires, you must remove a rope from service if it shows other signs of excessive wear, corrosion, kinking, crushing, bird-caging, or other defects that could affect strength or safe use. This is stated in 1919.24(e).

• Look for corrosion between wires, flat spots from crushing, severe kinks or bends that change lay, and bird-caging where strands separate.
• Pay special attention to areas that run over drums or sheaves or are near fittings.

Cite: 1919.24(e).

The wire rope splicing rules are in [Part 1919], specifically 1919.24, which is part of OSHA's maritime standards and applies to operations covered by Part 1919.

• Use these rules when working in maritime settings governed by Part 1919; other maritime parts (like Part 1918) may also apply to specific equipment or activities.

Cite: 1919 and 1919.24.

You must give special attention to rope sections not normally exposed and inspect them by exposing the area or removing fittings as needed so you can see the wire condition, per 1919.24(e).

• Loosen or remove thimbles, sleeves, or fittings where safe and practical to inspect the rope under or near those attachments.
• If inspection requires disassembly that affects safe operation, perform the work per lockout/tagout and manufacturer procedures and document the inspection.

Cite: 1919.24(e).

It means that for the two final tucks of the eye splice you remove (cut out) one-half of the individual wires in each strand so the remaining wires can be tucked and the splice finished; this specific method is required by 1919.24(a).

• Practically, you follow the standard splice technique where the early tucks use full strands and the last two tucks are completed after cutting out half the wires to avoid excess buildup and to seat the splice properly.
• Follow manufacturer or qualified rigger procedures to ensure the splice is made correctly.

Cite: 1919.24(a).