Safety Bulletin – Communication During Cable Handling Operations
During generator installation activities, an Encore team was stabbing 750 mcm cables into a generator. As part of the process, the crew stripped the cable and began sliding a connector onto the wire. The normal work practice for this task requires multiple crew members to coordinate, and team lift sections of the cable while the connector is worked down the conductor.
While this activity was taking place, one employee positioned near the tail end of the cable moved in to grab and assist with the lift. Before the employee could establish a firm grip, crew members further up the line adjusted their positions and shifted the cable unexpectedly. The movement caused the cable to strike the employee in the mouth, resulting in a chipped front tooth.
The review determined the primary cause of the incident was a breakdown in communication and coordination between crew members during the lift and adjustment process. Not all employees involved were aware the cable was about to be repositioned, and the movement occurred before everyone was ready and properly engaged.
Key Lessons Learned
- Large conductors such as 750 cables can shift suddenly and unpredictably when being lifted, repositioned, or adjusted.
- Team lifts and cable handling operations require clear communication and confirmation from all crew members before movement occurs.
- Employees should never assume others are ready or in position during coordinated lifting activities.
- Hands, body position, and face placement should remain clear of potential pinch points and unexpected cable movement zones until communication is confirmed.
Expectations Moving Forward
- Establish one designated lead person during cable handling operations to direct movements and communication.
- Use clear verbal commands such as “Ready,” “Lifting,” “Adjusting,” and “Hold” before any movement occurs.
- Ensure all crew members acknowledge they are ready before lifting or repositioning cable.
- Stop working immediately if any crew member is not in position or communication becomes unclear.
- Maintain situational awareness and avoid positioning your face or body directly in the path of possible cable movement.
Incidents like this reinforce that even routine tasks can result in injuries when communication and coordination break down. Taking an extra moment to ensure the entire crew is ready and working together can prevent injuries and keep everyone safe.