ELE/Cable Work/TBT-ELE-036
Cable Pulling and Drum Handling Safety
Electrical Safety › Cable Work › Cable Pulling and Drum Handling Safety
Toolbox Talk
Cable Pulling and Drum Handling Safety
Cable pulling involves drawing electrical cables from heavy drums through ducts, trenches, or containment systems over long distances. The cable drums are extremely heavy, the pulling forces are high, and the operation requires coordination between the drum end and the pulling head. This talk covers the hazards of cable pulling operations and the controls that protect every operative involved.
Key Hazards
Crushing injuries from uncontrolled cable drum movement during setup or transport
Hand and finger entrapment between the cable and duct entry during pulling
Cable whip if the pulling rope or cable breaks under tension during the pull
Back injuries from manual handling of heavy cable drums without mechanical aids
Control Measures
- Use a drum stand, turntable, or forklift to position cable drums — never roll them manually on site.
- Inspect the cable route for obstructions, sharp edges, and correct duct alignment before pulling begins.
- Apply approved cable lubricant to reduce friction and pulling force through the duct system.
- Use a calibrated pulling winch and monitor the pulling tension to stay within the cable's rated limit.
- Keep hands clear of the duct entry point and cable guides during the entire pulling operation.
- Station a banksman at the drum end and pulling head with radio communication between both positions.
- Ensure the cable route is clear of other workers who could be struck by a broken cable or rope.
- Wear gloves with good grip and avoid loose clothing that could be caught in the rotating drum.
- Record the pulling tension, cable length, and any damage observations in the installation log.
Remember
- Use a drum stand or forklift to position cable drums — never roll heavy drums manually
- Inspect the cable route for obstructions and sharp edges before any pulling operation begins
- Monitor pulling tension with a calibrated winch and stay within the cable's rated pulling limit
- Keep hands well clear of duct entry points and cable guides throughout the pull
- Station a banksman at both the drum end and pulling head with radio communication between them
- Record pulling tension, cable length, and any damage in the installation log for traceability
Applicable Legislation: Electricity at Work Regulations 1989 · PUWER 1998 · Manual Handling Operations Regulations 1992 · Health and Safety at Work etc. Act 1974
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