Winch operation safety requirements

Under 1918.53(a) moving parts of winches and other deck machinery must be guarded to prevent worker contact and entanglement. See 1918.53(a).

• Guards should cover belts, gears, shafts, sprockets, and any exposed rotating or reciprocating parts.
• Guards must be strong, secured, and arranged so they cannot be easily removed while machinery is in operation.

Cite: 1918.53(a).

Under 1918.53(b) winches must not be used if control levers operate with excessive friction or excessive play. See 1918.53(b).

• Excessive friction can prevent prompt control; excessive play can delay or prevent operator response.
• If you find these problems, take the winch out of service until a qualified person repairs the controls.

Cite: 1918.53(b).

Under 1918.53(c) double-gear winches or other winches equipped with a clutch must not be used unless a positive means of locking the gear shift is provided. See 1918.53(c).

• A ‘‘positive means’’ means a device or mechanism that prevents accidental or unintended gear changes during operation.
• If your winch lacks such a lock, do not operate it until one is installed and tested by qualified personnel.

Cite: 1918.53(c).

Under 1918.53(d) there must be no load on a two-gear winch other than the fall and cargo hook assembly when changing gears. See 1918.53(d).

• This means you must not have cargo or additional tension on the drum beyond the hook assembly while shifting gears.
• If a load is present, lower or secure it so the only weight on the winch is the hook assembly before changing gears to avoid sudden movements or gear damage.

Cite: 1918.53(d).

Under 1918.53(e) any winch defect or malfunction that could endanger employees must be reported immediately to the officer in charge of the vessel, and the winch must not be used until the defect or malfunction is corrected. See 1918.53(e).

• Immediately tag or otherwise mark the winch as unsafe and remove it from service.
• Ensure repairs are done by qualified personnel and re-inspect before returning the winch to operation.

Cite: 1918.53(e).

Under 1918.53(f) temporary seats and shelters for winch drivers that create a hazard to the winch operator or other employees must not be used. See 1918.53(f).

• Temporary seats or makeshift shelters that obstruct views, interfere with controls, or could collapse are prohibited.
• Use only properly designed, secured seating and shelters that allow safe access to controls and clear sightlines.

Cite: 1918.53(f).

Under 1918.53(g) winch drivers may not use winch control extension levers except for short handles on wheel-type controls, unless the levers are provided by the ship or the employer and meet specified strength and fastening requirements. See 1918.53(g).

• Approved extension levers must be of adequate strength and securely fastened with metal connections at the fulcrum and at the permanent control lever.
• Employers or the ship must supply and inspect these extensions; do not allow homemade or unsecured extensions.

Cite: 1918.53(g).

Under 1918.53(h) any extension control lever that tends to fall due to its own weight must be counterbalanced. See 1918.53(h).

• Counterbalancing prevents the lever from unintentionally moving the control and causing an uncontrolled hoist or lowering.
• Inspect extension levers regularly and repair or adjust counterbalances if you notice drift or unintended movement.

Cite: 1918.53(h).

Under 1918.53(i) winch brakes must be monitored during use, and if the brakes are unable to hold the load the winch must be removed from service. See 1918.53(i).

• Stop operations immediately, secure the area, and tag the winch "out of service."
• Arrange for qualified maintenance to repair or replace the brake and verify its holding capacity before returning the winch to use.

Cite: 1918.53(i).

Under 1918.53(j) winches shall not be used when one or more control points, either hoisting or lowering, are not operating properly; only authorized personnel may adjust control systems. See 1918.53(j).

• Stop use immediately if any control point is faulty, and restrict adjustments to trained, authorized technicians or operators designated by the employer.
• Document the fault, notify the officer in charge or supervisor, and verify full function after repair before resuming operations.

Cite: 1918.53(j).

Under 1918.53(k) when winches are left unattended, control levers must be placed in the neutral position and the power shut off, or control levers must be locked at the winch or at the operating controls. See 1918.53(k).

• Options are: (1) Neutralize controls and shut off power, or (2) lock the control levers in a way that prevents operation from either the winch or the remote controls.
• Ensure locks or power-off procedures are secure and that authorized personnel know how to return the winch to service safely.

Cite: 1918.53(k).

Under the crane operator medical condition interpretation, an operator must be physically able to perform assigned tasks without unscheduled interruption and may not leave controls while a load is suspended; the same safety principle applies to winch operators under relevant winch rules such as 1918.53(j) and 1918.53(k). See OSHA letter Crane operator medical condition scenario.

• If a winch operator becomes incapacitated or must leave controls while a load is suspended, that creates a hazardous condition and operations should be stopped and the load secured.
• Employers must assign only personnel who can complete lifts without unscheduled interruptions, and have procedures for immediate intervention if a problem develops.

Cite: 1918.53(j), 1918.53(k), and OSHA interpretation on crane operator medical condition.

Under 1918.53(g) employers should not allow employees to use homemade extension control levers because only levers provided by the ship or employer and meeting strength and fastening requirements are permitted. See 1918.53(g).

• Approved extensions must be of adequate strength and securely fastened with metal connections at the fulcrum and at the permanent control lever.
• If an employee brings a homemade lever, do not permit its use; instead provide a compliant extension or alternative control method.

Cite: 1918.53(g).

Under 1918.53(i) employers must monitor winch brakes during use and remove the winch from service if the brakes cannot hold the load. See 1918.53(i).

• Implement checks before and during lifts (visual inspection, test holds with rated loads, listen for slipping).
• If any sign of brake weakness appears (slippage, overheating, abnormal noise), stop operations, tag the winch out of service, and have repairs performed by qualified personnel.

Cite: 1918.53(i).

Under 1918.53(d) the rule about loads while changing gears references the fall and cargo hook assembly, and OSHA guidance on hooks explains that latches should be used where they prevent accidental disengagement; employers should use latch-type hooks unless the application makes them impractical. See 1918.53(d) and OSHA's hook latch interpretation Safety latches on sling hooks.

• Use hooks with self-closing safety latches or other positive securing means whenever possible to prevent accidental load disengagement.
• If a latch is impractical, document the justification and use other positive methods (e.g., shackles, bridles, or secured attachments).

Cite: 1918.53(d) and OSHA interpretation on safety latches.

Under 1918.53(g) extension control levers provided by the ship or employer must be securely fastened with metal connections at the fulcrum and at the permanent control lever, so a loose lever must be repaired or removed from service. See 1918.53(g).

• Tag the extension as defective, stop using it, and have a qualified person tighten or replace the metal connections.
• Do not allow operation with insecure connections because they can slip or fail and cause loss of control.

Cite: 1918.53(g).

Under 1918.53(k) locking the control levers at the operating controls is an acceptable alternative to shutting off power when leaving a winch unattended, so locking the levers while power remains on is compliant provided the locks prevent operation. See 1918.53(k).

• Ensure the locks are robust and prevent any accidental activation; test that locked controls cannot be operated before leaving the winch.
• Keep keys or unlocking authority under employer control so only authorized personnel can restore operation.

Cite: 1918.53(k).

Under 1918.53(e) any defect or malfunction of winches that could endanger employees must be reported immediately to the officer in charge of the vessel, and the winch must not be used until corrected. See 1918.53(e).

• Immediately stop using the winch, tag it as unsafe, and notify the officer in charge or supervisor.
• Arrange for qualified repair, verify the defect is corrected, and document the repair and testing before returning the winch to service.

Cite: 1918.53(e).

Under 1918.53(j) "authorized personnel" means trained and designated persons who have the knowledge and employer authority to safely adjust winch control systems; only these people may make adjustments. See 1918.53(j).

• Employers should document who is authorized (e.g., maintenance technicians, certified operators) and provide training and procedures for adjustments.
• Unauthorized tinkering by untrained employees is prohibited because improper adjustments can create dangerous failure modes.

Cite: 1918.53(j).

Under 1918.53(i), (e), and (j) employers must monitor winch brakes during use, report and take defective winches out of service, and ensure only authorized personnel adjust control systems. See 1918.53(i), 1918.53(e), and 1918.53(j).

• Create pre-shift and during-use brake checks and document results.
• Establish a clear defect-reporting procedure to notify the officer in charge and tag equipment out of service.
• Maintain a list of authorized personnel, provide training for control adjustments, and require qualified repairs with post-repair testing before return to service.

Cite: 1918.53(i), 1918.53(e), 1918.53(j).

Under 1918.53(g) short handles on wheel-type controls are an exception and may be used; other extension levers must be provided by the ship or employer and meet fastening and strength requirements. See 1918.53(g).

• Short wheel handles intended by design are acceptable, but long extensions or makeshift handles are not allowed unless employer-supplied and properly secured.
• Inspect short handles regularly for wear and secure attachment to prevent failure.

Cite: 1918.53(g).

Under 1918.53(i) and 1918.53(e) if a winch brake slips intermittently you must stop use, report the defect to the officer in charge, and remove the winch from service until the brake is repaired and tested. See 1918.53(i) and 1918.53(e).

• Immediately secure the load, tag the winch out of service, and prevent further operation.
• Have authorized maintenance diagnose and fix the brake, perform a load-holding test, and document repairs and testing before return to service.

Cite: 1918.53(i) and 1918.53(e).