What are the signs that a wire rope is no longer safe to use?

1. Visible Broken Wires

• Few Broken Wires: A small number of broken wires can occur during normal use, but if there is a significant number, especially in critical areas like the core or the eyes, the rope's integrity is compromised. It is a sign that the rope can no longer bear the required load safely.
• Particularly Important: If you see broken wires over a localized area or multiple breaks, it's time to replace the rope.

2. Excessive Wear or Flattening

• Wear: Prolonged use, especially with rough surfaces or abrasive materials, will cause the rope’s surface to wear down. This reduces the rope’s diameter and compromises its strength.
• Flattening: If the rope becomes excessively flat or deformed, this suggests structural damage, which means it can no longer bear the intended load without a higher risk of failure.

3. Corrosion or Rust

• Surface Corrosion: Exposure to moist or corrosive environments (such as saltwater or acidic chemicals) will cause rust and corrosion on the wire rope. Corrosion significantly reduces the rope's strength and resistance to wear.
• Internal Corrosion: In ropes with an Independent Wire Rope Core (IWRC), internal rust or damage can be harder to detect, but it drastically weakens the rope’s load-bearing capacity. Corrosion inside the rope may occur in moist environments and compromise its strength.

4. Severe Kinking or Twisting

• Kinks and Twists: Improper handling or usage can cause severe kinking or twisting of the wire rope. These deformations can prevent the rope from bearing a uniform load and lead to sudden failure.
• Unnatural Bends: If the rope shows visible bending or hard kinks, it suggests the rope has undergone significant damage, making it unsafe to use.

5. Loss of Flexibility

• Stiffness: Over time, the lubrication in the rope can wear off, leading to stiffness. If the rope becomes rigid and difficult to handle, it’s an indication that it has lost its necessary flexibility and could break under load.
• Lack of Movement: If you notice the rope is less pliable and no longer behaves like a new rope, it may be losing its strength and flexibility, which can increase the risk of failure.

6. Bulging or Excessive Elongation

• Bulging: If a wire rope begins to swell or bulge, particularly at high-stress areas, it usually indicates internal damage or an overload. The rope can no longer handle the intended load safely.
• Excessive Elongation: If the rope stretches significantly beyond its normal elongation range, it’s no longer safe to use. Excessive stretch means the rope’s load-bearing capacity has been compromised.

7. Lack of Lubrication

• Dry Rope: Lubrication is essential for reducing friction and wear. If the rope is dry or shows signs of inadequate lubrication, it will wear out faster, increasing the risk of damage or breakage.
• Loss of Protective Coating: If the rope’s protective coating is worn off, it exposes the steel wires to moisture and contaminants, accelerating wear and corrosion.

8. Abrasion Damage

• Abrasion Marks: If the rope’s surface shows significant wear, especially from contact with rough surfaces or abrasive materials, it can lose its original strength and durability.
• Scratches and Cuts: Deep scratches, nicks, or cuts on the rope surface can lead to weak points where the rope is more likely to break.

9. Internal or External Damage

• Internal Damage: In ropes with an IWRC, damage to the core, such as internal rust or broken wires, can severely affect the rope’s overall strength. Internal damage is difficult to detect visually but can significantly impair the rope's integrity.
• External Damage: If the outer strands of the rope are damaged, frayed, or showing wear, the rope may no longer be capable of withstanding its rated load, even if the internal core seems intact.

10. Excessive Stretching

• Overstretched Rope: Some wire ropes may exhibit small deformations or stretching under excessive load, which might not cause immediate breakage but will significantly weaken the rope over time. If the rope shows signs of stretching or “slackness,” it indicates the loss of strength.

These signs indicate that the wire rope is no longer safe to use, and immediate inspection or replacement is necessary. If any of these symptoms occur, it is crucial to replace the rope to ensure safety.