Failure Investigation and Analysis
Rope and Cable Failure Analysis
While rope and cable failures should be prevented at all costs, when they do occur, thorough investigation and analysis are essential to avoid recurrence—especially given the high stakes, which can include significant financial loss, operational downtime, and, in the worst cases, fatalities.
Failure investigation of ropes and cables is a specialised field within the broader discipline of failure analysis. It demands a deep understanding of mechanical engineering, material science, and the specific application environments in which these components are used. This includes a wide range of sectors and uses, such as:
Mooring and marine towage
Industrial lifting and rigging
Construction
Commercial and recreational fishing
Climbing and zip-lining
General utility and infrastructure operations
Each context presents unique stresses, wear patterns, and environmental conditions that influence the longevity and performance of ropes and cables. As such, effective failure analysis not only identifies the mode and cause of failure (e.g., fatigue, abrasion, corrosion, overload, manufacturing defects), but also helps improve maintenance protocols, design standards, and operational procedures to enhance safety and reliability.
Expert Analysis of Rope and Cable Failures
At TTI, our experts bring extensive experience in investigating rope and cable failures across a range of industries and environments. Our thorough procedures are designed to identify the underlying causes of failure and estimate the likely load at the point of failure.
We employ a wide array of analytical techniques, including:
Digital and Scanning Electron Microscopy (SEM)
Rope and yarn strength and elongation testing
Chemical composition analysis
Where appropriate, Optimoor Mooring Analysis
In addition to assessing the physical condition of the rope, we calculate rope strength and analyse environmental loads, such as wave and current loading, to better understand the operational context of the failure.
TTI also provides expert witness services and delivers clear, evidence-based recommendations—whether to improve rope selection, optimize equipment design, or enhance operational practices.
Our goal is to help clients prevent future failures through better materials and more considerate equipment design.
Common causes of failure include:
Mechanical and Structural Failures
· Overloading / Over-tensioning: Exceeding the ropes/cables rated capacity
· Shock Loading: Sudden dynamic forces far exceeding static load ratings.
· Abrasion: Surface damage from friction or contact with rough edges.
· Cutting / Shearing: From sharp surfaces or improper handling.
· Kinking or Crushing: Deformation due to poor storage, knotting, or misuse
Environmental Factors
· UV Degradation: Prolonged exposure to sunlight weakens synthetic fibres.
· Chemical Exposure: Oils, acids, or alkalis degrading rope integrity.
· Moisture: Water absorption weakening fibres or causing natural fibres to rot.
Manufacturing Defects
· Materials: Poor materials or material inconsistency
· Production Processes: Substandard rope production and QA/QC controls
· Termination: Poor or inefficient splices.
Improper Usage
· Incorrect rope/material selection for application
· Ignoring manufacturing and industry guidance
· Incorrect rigging or interface selection
· Reusing damaged ropes
