What are signs of damaged or worn wire rope, and when should it be removed from service?

• A. Broken strands, birdcaging, flat spots, corrosion, kinking, crushed or cracked strands, or rope diameter loss; remove from service when damage exceeds manufacturer or regulatory limits.
• B. Ropes turning blue; continue use.
• C. Occasional fraying is acceptable; no removal.
• D. Only visible rust dictates removal.

Answer: (A)

Signs of damaged or worn wire rope include broken strands, birdcaging, flat spots, corrosion, kinking, crushed or cracked strands, or rope diameter loss. These conditions mean the rope’s strength has been compromised and it can fail suddenly under load. The rope must be removed from service when the damage exceeds what the manufacturer or applicable safety regulations allow, so it can be replaced before a lift failure occurs. A qualified person should assess and make the call to remove, based on specific limits set by the rope maker or regulators.

Other choices don’t fit standard inspection criteria. Turning blue isn’t a recognized warning sign for wire rope wear. Occasional fraying isn’t acceptable as a condition to keep using rope, since it can hide more serious internal damage. And removal isn’t dictated by visible rust alone; corrosion must be severe enough to meet the defined limits before it warrants taking the rope out of service.