Safety in Winch Work: Not an Afterthought

Electric winches are powerful machines that can move thousands of pounds. With that power comes responsibility. Serious accidents occur annually due to unsafe winch work, often from avoidable mistakes.

Mistake 1: Wrong Pull Angle

The Problem

When the cable comes onto the drum at too sharp an angle, problems arise:

• Uneven loading of the drum
• Excessive wear on cable and guide
• Risk of cable jumping off
• Reduced pulling power

The Solution

• Always use a fairlead to guide the cable
• Keep the pull angle as straight as possible (maximum 15° deviation)
• For larger angles: relocate the anchor point or use an additional pulley
• View our range of fairleads

Mistake 2: Too Little Cable on the Drum

The Problem

A winch’s pulling power is highest when there’s little cable on the drum. But:

• The last wraps are secured with a weak retention bolt
• This bolt is intended as emergency protection, not for pulling power
• Maximum pulling power can break the retention bolt

The Rule

Always keep at least 5 complete wraps on the drum

In Practice

• Measure how much cable you can unroll
• Mark the cable at the point where 5 wraps remain
• Use a snatch block to increase effective reach

Mistake 3: Ignoring the Duty Cycle

The Problem

Every electric winch has a duty cycle: the maximum operating time before the motor must cool down. Typical duty cycles:

• Consumer winches: 30% (3 minutes on, 7 minutes off)
• Professional winches: 50% (5 minutes on, 5 minutes off)

Overheating leads to:

• Reduced power
• Motor damage
• Melting insulation
• Fire

The Solution

• Work in short intervals with sufficient pauses
• Feel the motor: hot = take a break
• For intensive use: choose a 24V winch with higher duty cycle
• Run the engine for extra cooling

Mistake 4: No Damping on the Cable

The Danger

When a cable breaks, steel cable snaps back with deadly force. Even Dyneema, although safer, can cause injury.

The Solution: Line Damper

Always hang a line damper (winch damper) over the tensioned cable:

• Absorbs energy during breakage
• Drastically reduces recoil
• Can be a jacket, blanket, or bag

Placement

Hang the damper at approximately 1/3 of the cable length from the winch. For long distances: use multiple dampers.

Mistake 5: Wrong Anchor Points

Dangerous Anchor Points

• Trees: Can crack or uproot
• Guardrails: Not designed for lateral forces
• Other vehicles: Only with proper tow eye, never to bumper
• Light objects: Anything lighter than your vehicle

Good Anchor Points

• Ground anchors: Specially designed for winch work
• Trees with tree saver: Distribute force across the trunk
• Heavy vehicles: With correct tow eye, engine running, handbrake on
• Rocks/concrete blocks: Stable and heavy enough

Mistake 6: Hands Near the Drum

The Risk

The drum rotates with force. Fingers or clothing that get caught are pulled in.

The Rules

• Never put hands near the drum during operation
• Wear gloves when handling steel cable
• Don’t wear loose clothing or jewelry
• Keep everyone away from the winch during operation

Mistake 7: Winching Without Communication

The Problem

Winch work often involves multiple people. Without clear communication, misunderstandings arise:

• Unexpected starting of the winch
• People in the danger zone
• Wrong driving direction

The Solution

• Agree on clear hand signals
• One person operates, one person gives directions
• Ensure everyone is outside the danger zone
• Use a remote control to stay at a safe distance yourself

View our remote controls and wired controls.

Safety Checklist

Before every winch session:

• Cable inspected for damage
• Minimum 5 wraps on drum
• Fairlead correctly aligned
• Anchor point secure and suitable
• Line damper placed
• Bystanders at safe distance
• Communication agreed upon
• Gloves on (steel cable)

Questions About Safe Winching?

Our specialists are happy to share their knowledge about safe and effective winch work. Contact us for advice or training.