Using a winch safely is crucial to ensuring the well-being of operators and bystanders, as well as the integrity of the equipment being used.
With over three decades of industry expertise, the team at Red Rooster Lifting knows how important winch safety is.
Read on for a breakdown of the essential guidelines from the LEEA Code of Practice for the Safe Use of Lifting Equipment (COPSULE)* to follow for safe winch operation.
1. Transportation
When transporting, handling, or lifting a winch, always use only the means provided for that purpose, such as designated lifting eyes or mounting points. Never attempt to lift the winch by its drum, operating handle, or drive shaft. These components are not designed to bear the winch’s full weight and can be easily damaged, creating a future point of failure. Using a sling through the winch frame is a safe alternative if no specific lifting points are provided.
2. Rigging method
Ensure the rigging method used is adequate for the load to be lifted. This means that not only the winch itself but also its fixings, suspension pulleys, and the suspension points of pulley blocks must be capable of handling the imposed loads. Be aware that the load on the rigging can be significantly higher than the weight of the object being lifted due to factors like friction and the angle of the rope. A qualified rigging professional should always be consulted to verify that your setup can handle the total forces involved.
3. Keep brakes contamination-free
Maintaining the integrity of the brake system is non-negotiable. Take all necessary steps to prevent water, oil, or other foreign matter from coming into contact with the lined brakes within manually operated winches. Contamination can drastically reduce the friction of the brake pads, causing the brake to lose its effectiveness.
4. Direction of rotation
When performing an inspection, it is critical to confirm the direction of rotation on the operating handle. For a manual winch, ensure that the winch correctly lifts the load when the handle is turned in the indicated direction. Operating the winch in the wrong direction could lead to the load dropping unexpectedly or the operator losing control.
5. Check the control system for powered hoists
For powered winches, the control system is a primary safety feature. Please make sure that the E-stop (emergency stop) functions as designed, immediately cutting power and stopping all motion when activated. Test the raise and lower functions to ensure they are working correctly, and that the controls are responsive and consistent, without any sticking or hesitation. Finally, check that all control pendants, buttons, and switches are clearly labelled and free from damage, ensuring the operator can command the hoist with precision and confidence.
6. Correct fitting of operating handles
In the case of manually operated winches, it’s essential to ensure that operating handles are correctly fitted and securely fastened before attempting to use the winch. An improperly fitted handle can come loose under load, causing the operator to lose control of the winch. This can lead to the load dropping suddenly and dangerously, potentially causing serious injury to the operator or anyone nearby.
7. Correct use of sliding gears
If the winch is fitted with sliding gears, always ensure the gears are correctly in place and that the locking device is properly applied. This locking mechanism is designed to prevent the gears from disengaging whilst under load. If the gears were to slip out of position while lifting, it could cause the load to drop without warning. A quick check of the gear engagement before every lift is a simple but vital safety step.
8. Check brake integrity
The brake or sustaining mechanism is the most critical safety device on any winch. Before making any lift, perform a simple but essential check of its integrity. Raise the load just clear of the ground and halt the lift. The load should be sustained with no downward movement. If the load slips even slightly, the winch must be taken out of service immediately for professional inspection. This pre-lift test verifies that the brake can reliably hold the load.
9. Check the wire rope
Before operating the winch, a detailed inspection of the wire rope is a must. Ensure the rope is not twisted, kinked, or frayed. Check that it is correctly positioned in all pulleys and is able to move freely without snagging. Wire ropes in positions that may be dangerous during movement must be guarded. A whipping rope or a loose loop can cause severe lacerations or other injuries to personnel. Make sure adequate steps are taken to protect personnel and property from any hazards.
10. Stand clear of moving parts
This may seem obvious, but it is one of the most common causes of injury. Keep hands, feet, clothing, and all other parts of your body away from rotating parts, ropes, winch drums, pulleys, and similar danger areas. These components can cause trapping, crushing, or laceration injuries. Remember that even slow-moving ropes can be dangerous. Always stand in a safe place and keep a clear line of sight, ensuring you are out of the way of any moving equipment.
11. Always attend winches in use
Never leave a suspended load unattended; this poses a significant crush hazard. Steps must be taken to ensure that inadvertent or accidental operation of the winch cannot occur. When a lift is complete and the load is secured, the winch should be isolated or its controls locked out to prevent any accidental activation.
12. Use the right winch for man-riding
Man-riding winches are extremely high-risk and require specialised equipment. These winches have additional safety features, such as redundant braking systems and higher safety factors, to protect human life. Using a standard hoist for man-riding is strictly prohibited and could result in serious injury or fatality, so always follow the manufacturer’s instructions for both rigging and operation.
13. Correct rope positioning
Care must be taken to ensure that the correct amount of rope is wound onto or off the winch drum. Over-winding can cause the rope to stack and damage itself or the drum’s flanges, while under-winding can lead to the rope detaching from the drum. If limits or stops are fitted, they are a safety device intended to prevent these issues and should not be used as working stops for load positioning.
Talk to your lifting experts
If you’re looking for more support on how to use winches for your application safely, get in touch with the lifting experts at Red Rooster Lifting. Our team are on hand to guide you on the safe use of winches from reputable brands like Gebuwin and EMCE.
We have a range of bespoke maintenance contracts, including LOLER Examinations, ensuring your site is operating to safe industry standards.
Talk to the team at Red Rooster Lifting today to get started.
*For further reading, download the full COPSULE document on the LEEA website.Â