Cable Hauling Safe Work Method Statement

Manual cable pulling should be limited to forces not exceeding 250 Newtons (approximately 25 kilograms force) sustained over pulling duration. Even at this level, pulls should not exceed 30 metres distance or involve more than two 90-degree bends totalling 180 degrees of direction change. Beyond these limits, mechanical pulling using winches becomes necessary to prevent manual handling injuries. Calculate estimated pulling force before commencing work based on cable weight, conduit friction, and bends in route. Cable manufacturers provide pulling tension calculators or charts estimating force requirements. For 4mm² cable through 20 metres of conduit with one 90-degree bend, pulling force is approximately 150N well within manual pulling capability. For 16mm² cable through 40 metres with three bends, estimated force exceeds 500N requiring mechanical pulling. Apply cable pulling lubricant significantly reducing friction particularly for long pulls through multiple bends. Lubricant can reduce pulling force by 30-50% compared to dry pulling. Use team pulling for forces approaching manual limits with workers coordinating effort through communication. Position workers to apply steady pulling force maintaining straight posture with force applied through legs rather than back. Never jerk or apply impact loads which create force spikes damaging cable and injuring workers.

Prevent cable damage by implementing multiple controls working together. First, obtain cable manufacturer maximum pulling tension specifications before planning installation - typically 50N per mm² of conductor cross-sectional area for copper conductors. For 35mm² cable, maximum is 1750N; for 95mm² cable, maximum is 4750N. Second, use cable winches incorporating load cells or tension monitoring displaying real-time pulling force. Set alarm at 80% of maximum permitted tension providing warning before damage occurs. Third, calculate estimated pulling force before commencing work based on cable weight, conduit friction coefficient, and bends in route using cable manufacturer calculation methods. If estimated force approaches limits, redesign route to reduce bends or install intermediate pull points breaking pull into shorter sections. Fourth, apply cable pulling lubricant liberally reducing friction between cable and conduit - lubricant reduces pulling force 30-50% particularly important for long pulls. Fifth, ensure conduit system is properly aligned without offset joints, sharp edges, or blockages causing binding and excessive friction. Sixth, monitor cable condition during pulling watching for signs of over-tension including insulation stretching, conductor exposure, or jacket distortion. Stop immediately if damage is observed. Seventh, for multi-conductor cables, use proper pulling grips distributing tension across cable structure rather than pulling on conductors directly. Eighth, never exceed winch speed recommendations as excessive speed increases friction and tension. Maintain steady controlled pulling speed matching feeding rate from drum.

Confined space procedures for cable pit entry include multiple mandatory controls. First, identify all pits and manholes as confined spaces requiring formal entry procedures - pits deeper than 1.2 metres with restricted access are confined spaces under WHS regulations. Second, conduct atmospheric testing before entry using calibrated gas detector measuring oxygen content must exceed 19.5 percent, flammable gas must be zero, and toxic gases must be below exposure limits. Third, provide continuous mechanical ventilation using portable blower positioned at pit opening forcing fresh air into space - maintain ventilation throughout occupation period. Fourth, issue personal gas detector to each worker entering pit with alarms set for oxygen depletion below 19.5%, flammable gas above 10% LEL, and relevant toxic gases. Fifth, position trained standby person at pit opening who does not enter space but maintains constant communication with entrant. Standby person must not enter for rescue but summons trained rescue team. Sixth, provide emergency retrieval equipment including tripod and winch, rescue harness worn by entrant, and retrieval line attached to entrant's harness dorsal D-ring. Seventh, establish communication protocol requiring entrant to respond to standby person checks every 5 minutes - failure to respond triggers rescue procedures. Eighth, limit continuous time in confined pit to 30 minutes particularly in hot conditions before rotating workers to fresh air break. Ninth, brief all workers on entry procedure, communication requirements, hazards, and emergency procedures including rescue. Never enter confined space without implementing these procedures - numerous fatalities have resulted from uncontrolled confined space entry.

Coordination between separated pulling and feeding crews requires reliable communication system and clear protocols. Use two-way radios programmed to dedicated channel eliminating interference from other site communications. Test radios before commencing pulling verifying clear audio in both directions and adequate battery charge for pulling duration. Establish communication protocol including standard phrases and response requirements. Typical protocol: winch operator announces "Ready to pull" and waits for feeding crew response "Ready to feed" before starting. Winch operator announces "Starting pull" before applying tension. During pulling, maintain open communication with feeding crew reporting drum rotation status and any problems observed. Winch operator reports pulling tension and speed adjusting to match feeding rate. If feeding crew reports drum not rotating smoothly or cable tangling, winch operator immediately stops pull. Establish emergency stop procedure where either crew can call "Stop pull" and other crew immediately stops operations. If communication is lost during pulling, immediately stop pulling operation and do not resume until communication is restored. For very long cable runs where radio communication may be unreliable, position intermediate crew member at midpoint relaying communications between ends. Never attempt cable pulling when communication cannot be maintained - risk of over-tensioning cable or entrapping workers requires continuous coordination. For critical or complex pulls, conduct pre-pull briefing bringing pulling and feeding crews together to discuss sequence, communication protocol, tension limits, and emergency procedures. Practice communication protocol during equipment setup verifying all crew members understand and can execute procedures.

Service location before excavation requires systematic approach ensuring all buried services are identified. First, contact Dial Before You Dig (1100) minimum 2 business days before planned excavation providing location details and work description. Utility owners respond with service location plans showing underground assets in work area including electricity, gas, water, telecommunications, and sewer services. Second, review service plans from all responding utilities noting services shown crossing or adjacent to proposed excavation. Plans indicate approximate service locations but may not show exact depth or position particularly for older services. Third, engage qualified service locator to scan excavation area using electronic locating equipment capable of detecting electrical cables, telecommunications cables, metallic pipes, and some non-metallic services. Locators mark detected services using temporary spray paint following national colour code - red for electrical, yellow for gas, blue for water, orange for telecommunications. Fourth, hand dig trial holes at service crossing points exposing services to verify exact depth and horizontal position before commencing mechanical excavation. Trial holes must be excavated using hand tools within 500mm of indicated service location. Fifth, maintain minimum clearance distances from exposed services - 300mm from electrical cables and gas pipes, machinery prohibited within clearance zone. Use hand tools only for excavation within clearance distances. Sixth, assume all electrical services are energised unless confirmed isolated by asset owner and tested dead with voltage detector. Never rely on service age or visual appearance to judge energisation status. If unexpected service is discovered during excavation, immediately stop work and notify relevant utility before proceeding. Document service location activities including plans obtained, locating performed, and services found providing protection from liability if unidentified service is subsequently damaged.

Heat stress management for cable pulling requires proactive controls particularly during Australian summer when outdoor temperatures exceed 35 degrees Celsius or when working in confined pits. First, schedule physically demanding cable pulling during cooler morning hours before 11am when temperatures are lowest. Delay afternoon work if temperature exceeds 38 degrees Celsius and work can be rescheduled. Second, implement structured work-rest cycles allowing physiological recovery from heat exposure. Use 50 minutes work / 10 minutes rest cycle in moderate heat, reducing to 30 minutes work / 15 minutes rest when temperature exceeds 35 degrees Celsius or when working in confined spaces exceeding 40 degrees Celsius. Third, provide unlimited cold drinking water at work location in insulated containers maintaining water temperature below 15 degrees Celsius. Workers should consume minimum 200ml water every 15 minutes regardless of thirst sensation. Fourth, establish shaded rest area or air-conditioned vehicle allowing workers to cool down during rest breaks. Rest breaks in ambient heat provide little recovery benefit. Fifth, for confined pit work, limit continuous time in pit to maximum 20 minutes in hot conditions before mandatory rotation to fresh air. Position portable cooling fans at pit openings improving air movement for workers in pits. Sixth, assign supervisor to monitor workers for heat stress symptoms including heavy sweating progressing to dry skin, confusion, weakness, rapid heart rate, and loss of coordination. These symptoms indicate developing heat stroke requiring immediate medical attention. Seventh, allow workers to self-pace work intensity in extreme heat - some loss of productivity is acceptable to prevent heat-related illness. Eighth, provide cooling equipment including ice vests, cooling towels, or misting fans for workers in extreme conditions. Workers wearing full PPE including long sleeves and gloves face additional heat stress requiring enhanced controls. Never ignore heat stress symptoms or pressure workers to continue in unsafe conditions - heat stroke can cause permanent organ damage and death within 30-60 minutes if untreated.