Which signs indicate a damaged wire rope that requires removal from service?

• A. Normal wear.
• B. Recent lubrication.
• C. Paint chipping.
• D. Visible broken strands, bird caging, kinking, heat damage, corrosion, flattening.

Answer: (D)

Damaged wire rope shows signs of actual structural compromise, which means the rope can fail suddenly under load and must be removed from service to protect people and equipment. The key indicators are those that reveal internal or overall degradation of strength and integrity: visible broken strands reduce the rope’s ability to carry load; bird-caging occurs when the inner strands protrude and form a cage-like appearance, signaling broken strands and misalignment inside the rope; kinking creates sharp bends that introduce micro-cracks and stress concentrations; heat damage weakens the steel, softens coatings, and accelerates fatigue; corrosion eats away material, lowering cross-section and strength; flattening shows deformation from excessive wear or bending, indicating fatigue and reduced load-carrying capacity. When any of these are present, the rope is unsafe for continued use.

Normal wear, lubrication, or cosmetic paint chipping do not by themselves indicate immediate removal, though they should be monitored and addressed as part of ongoing rope maintenance.