Identify signs of damaged wire rope that require removal from service.

• A. Breakage or excessive corrosion; birdcaging or severe crushing; significant heat damage.
• B. Mild surface rust only.
• C. Slight bending with no wear.
• D. Normal wear from use.

Answer: (A)

When a wire rope is inspected, anything that shows a real loss of strength or internal damage means it should be removed from service. Breakage or excessive corrosion directly reduces the rope’s load-carrying capacity and can lead to sudden failure. Birdcaging, where internal strands have separated and the rope tubes puff out, reveals widespread internal damage and a high risk of rupture under load. Severe crushing changes the rope’s shape and stiffness, creating weak points that can kink or fail under tension. Significant heat damage indicates metallurgical changes and loss of lubrication, both of which weaken the rope and can cause unexpected breaks.

In contrast, mild surface rust, slight bending with no wear, or normal wear from use do not by themselves prove the rope has reached the end of its safe service life, though any wear should be monitored against applicable inspection criteria.