How many broken wires in one strand lay length indicate replacement?

• A. 1
• B. 2
• C. 3
• D. 4

Answer: (C)

When assessing wire rope, the number of broken wires in a strand within one lay length is a primary indicator of wear and safety. A lay length is the distance over which the strand makes one complete twist around the rope, so looking for broken wires within that small section focuses on fatigue where stresses concentrate.

Three broken wires in a single strand within one lay length means the strand has deteriorated enough that its remaining wires can no longer share load reliably. That level of damage drastically reduces the rope’s strength and increases the risk of sudden failure under normal service, so the rope should be replaced.

If there are fewer than three broken wires, the rope might still be serviceable depending on diameter and applicable standards, but once you reach three in one lay length, replacement is warranted.