Cable failure and whip

High

Lift cables under tension can snap and whip with enough force to cause lacerations, eye injuries, or broken bones

Cable replacementCable drum adjustmentSpring replacementDoor balancing

Hazard description

Lift cables bear the full weight of the door under spring tension. A worn, frayed, or corroded cable can snap without warning, whipping violently. The broken cable end can strike with enough force to cut skin, break bones, or cause eye injuries. Cables can also fail at the termination point (bottom bracket or cable drum) if hardware is worn or improperly secured.

What can go wrong

Cable snaps under load and whips across the workspace
Frayed cable strands cut hands during inspection or handling
Cable comes off the drum and the door falls or shifts
Cable breaks at the bottom bracket, releasing the door
Incorrectly sized cable fails prematurely under load

How to reduce or eliminate the risk

1
Inspect cables regularly for wear
Check lift cables for fraying, broken strands, kinks, rust, and wear at contact points (drum, bottom bracket, and any pulleys). Replace cables at the first sign of damage. Do not wait for complete failure.
2
Replace cables in pairs
If one cable is worn, the other is likely near the end of its life. Replace both cables at the same time to ensure even wear and balanced operation.
3
Use the correct cable size and type
Match the cable diameter and construction to the manufacturer's specification. Using undersized cable will cause premature failure. Galvanized aircraft cable is standard for overhead doors.
4
Secure the door before cable work
Clamp the door in the closed position before removing or adjusting cables. Releasing a cable while the door is unsupported can cause it to fall or shift suddenly.
5
Stand clear of the cable path
When tensioning cables or adjusting drums, keep your body and face out of the cable's path. If a cable fails, it will whip in the direction of travel.

Required PPE

Safety glasses with side shields
Heavy-duty leather gloves
Long sleeves
Steel-toe boots

References & standards

DASMA Technical Data Sheet #112: Cable Safety
Wire Rope Technical Board: Wire Rope Users Manual

How to reduce or eliminate the risk

Inspect cables regularly for wear

Check lift cables for fraying, broken strands, kinks, rust, and wear at contact points (drum, bottom bracket, and any pulleys). Replace cables at the first sign of damage. Do not wait for complete failure.

Replace cables in pairs

If one cable is worn, the other is likely near the end of its life. Replace both cables at the same time to ensure even wear and balanced operation.

Use the correct cable size and type

Match the cable diameter and construction to the manufacturer's specification. Using undersized cable will cause premature failure. Galvanized aircraft cable is standard for overhead doors.

Secure the door before cable work

Clamp the door in the closed position before removing or adjusting cables. Releasing a cable while the door is unsupported can cause it to fall or shift suddenly.

Stand clear of the cable path

When tensioning cables or adjusting drums, keep your body and face out of the cable's path. If a cable fails, it will whip in the direction of travel.