The rope is removed from the application due to various possible causes that includes accelerated wear, corrosion, kinks, stretch, pinching and crushing. Rope is no longer remain in service when the factor of safety become too low and there is loss in rope strength due to wear, corrosion or any form of deterioration.
| Fault | Possible Cause |
| Accelerated Wear | Severe abrasion from being dragged over the ground or obstructions. Rope not suitable for application. Poorly aligned sheaves Large fleet angle. Worn Sheave with improper groove, size or shape. Stiff or seized sheave bearings High bearings and contract pressures. Sheeves/drum two small |
| Rapid appearance of Brokn Wires | Rope not suitable for application Reverse bends. Sheaves drums too small. Overload and shock loads. Excessive rope vibration. Kinks that have formed and have been straightened out.. Crushing and flamering of the rope Sheave wobble. |
| Corrosion | Inadequate lubrication Improper storage Exposure to acids or alkalis. |
| Kinks | Improper installation. Improper handling Stack rope pulled tight. |
| Excessive localised Wear | Dru crushing. Equalizer Sheave Vibration. |
| Stretch | Overload Passed normal stretch and approaches failure. |
| Broken Wires near Fitting | Rope Vibration. Fitting get pulled too close to sheave or drum. |
| Sheaves/Drums Wear out | Material too soft. |
| Pinching, Crushing, oval Shape | Sheaves grooves too small. Not following proper installation and maintenance procedure on multiple layer drums. |
| Rope Unlays (Opens up) Reduction in Diameter | Wrong rope construction. Rope end attached to swivel. Brokern core. Overload. Internal Wear. Corrosion. |
| Bird Cage | Tight Sheaves. Rope is forced to rotate around it own axis. Shock loads. Improper Wedge Socket Installation. |
| Core Protrusion | Shock loading. Disturbed rope lay. Rope unlays. Load spins and rotates rope around its own axis. |
DISCARDING A WIRE ROPE : No rope staid remain in sevice when it is considered that:
a) The factor of safety has become too low (when the reserve of strength is no longer sufficient to ensure that the rope can safely withstand the repeated shock loads, bends, etc.)
b) The loss in rope strength due to wear, corrosion, or both is approaching one-sixth or 16 percent of the original strength (or any lower value set by the concerned engineer)
c) The loss in rope strength due to fatigue, corrosion-fatigue, or surface embrittlement or due to cracked or broken wires of any kind, is approaching one tenth of the original strength (or any lower value set by the concerned engineer).
d) The outer wires have lost about one third of their depth as a result of any form of deteroration.
e) The outer wires are becoming loose and displaced for any reason.
f) The rope has become kinked or otherwise deformed, distorted or damaged, and the affected part cannot be cut out.
g) The rope has been subjected to a severe overwind or overload or to severe shock loading, as a result of an accident if the portion of the rope so subjected cannot be cut off (as in the case of overwind above banking level).
h) The examination of the rope leaves any doubt to its safety on any grounds.
i) A rope, which is still in good condition, reaches the maximum life for its type prescribed by the manufacturer or as laid down in Regulations, if any.
