From Concern to Action: Improving Tether Rope Safety Across the Industry
One of the strengths of FICA is its ability to bring industry together to solve practical problems. The latest SafeTree Safety Alert on Tether Rope Failures in Winch-Assisted Harvesting is a great example of how a concern raised by a single contractor can lead to industry-wide action.
The work began when a FICA member approached us with concerns about the inspection, maintenance and replacement of tether ropes and associated rigging used in winch-assisted harvesting operations. While recent rope failures had not resulted in serious injury, they highlighted the potentially severe consequences that can arise when safety-critical components fail.
Rather than treating this as an isolated issue, FICA brought together a small working group comprising harvesting contractors, equipment manufacturers, wire rope specialists, researchers and safety practitioners. The group included representatives from across the sector, ensuring that contractor experience, manufacturer expertise and research knowledge were all reflected in the outcome. Through a series of discussions and reviews, the group developed the attached Safety Alert, which has now been published through SafeTree.
The key message from the alert is simple: tether ropes are safety-critical components and their management must be based on systematic inspection, condition assessment, maintenance records and recognised discard criteria. Decisions about rope replacement should be driven by safety and condition, not operating hours alone and certainly not by cost pressures.
However, throughout the discussions, one theme continued to emerge. While the industry has invested considerable effort in guidance material, best practice documents and safety alerts over recent years, awareness does not always translate into consistent field practices. The working group recognised that written guidance alone may not be enough to drive the behavioural change required.
As a result, FICA is now exploring a number of practical initiatives designed to support contractors, mechanics and operators in carrying out inspections and maintenance activities more consistently.
These include the development of a practical rope inspection and management video that would provide visual examples of common defects, deterioration mechanisms, discard criteria and good rope management practices. The intention is to create a resource that can be used in inductions, toolbox meetings, refresher training and operator development programmes.
FICA is also investigating the potential development of a digital inspection and maintenance App. Such a tool could assist contractors with pre-start inspections, maintenance records, rigging registers, photo documentation and service history tracking. Importantly, it could make it easier for crews to demonstrate that inspections are being completed and provide a consistent approach across the industry.
In parallel, discussions are underway about whether the inspection of winch-assist machines could be incorporated into the existing tower inspection framework. The current tower certification system provides an established inspection process, qualified inspectors, centralised records and an industry-recognised standard. Early feedback from industry stakeholders suggests there may be merit in exploring whether elements of this model could also be applied to winch-assist machinery.
FICA has recently approached FISC to assist with consultation and implementation of these concepts. Initial feedback has been encouraging, and there appears to be strong support for practical tools that make it easier for contractors and operators to maintain high standards of equipment inspection and maintenance.
Most importantly, this work demonstrates the value of members speaking up when they identify emerging risks or industry issues. The attached Safety Alert exists because one contractor took the time to raise a concern and start a conversation.
FICA would like to acknowledge and thank the member who highlighted this issue. Their willingness to raise a potentially uncomfortable topic has resulted in constructive industry-wide discussions and practical actions that have the potential to improve safety across the sector.
We encourage all members to continue bringing concerns, observations and improvement ideas to FICA. This is exactly the type of work the organisation should be enabling: identifying emerging issues, bringing the right people around the table, and working collaboratively to develop practical solutions that improve safety and performance for the entire forestry contracting industry.
