The manual wire rope winch is a compact, manually operated pulling and lifting device used on construction sites and in yard operations for the controlled moving, positioning, and securing of loads. In the context of concrete demolition, building gutting, rock breakout, tunnel construction, and natural stone extraction, it plays a supporting role: components are held before separation, fracture directions are secured, or heavy handheld tools are guided accurately. In combination with hydraulic tools from Darda GmbH—such as concrete demolition shear or rock and concrete splitters—the manual wire rope winch enables precise workflows without performing separating tasks itself.
Definition: What is meant by manual wire rope winch
A manual wire rope winch is a mechanical device with a crank drive and a cable drum that provides tractive force via a gear mechanism to pull, lift, or hold loads. Core components are the frame, cable drum, crank, gearbox, pawl or backstop, and a load-pressure brake. The pulling medium is usually a wire rope, more rarely a synthetic rope. Unlike cable pullers with clamping mechanics, the manual wire rope winch uses a take-up drum on which the rope is wound. It is suitable for controlled movements and holding tasks, for example securing concrete slabs prior to the use of concrete demolition shear or guiding block parts after splitting with hydraulic wedge splitter and concrete splitter.
Design and operating principle
The manual wire rope winch consists of a robust housing with bearings for the cable drum. The crank drives the drum via one or more reduction stages, creating a mechanical amplification of hand force. An automatic brake holds the load in any position as soon as the crank is not being moved. A pawl prevents backdriving; in higher-grade versions, a self-acting load-pressure brake enables sensitive lowering. The rope is attached with a thimble and hook or a shackle. Using snatch blocks, the pulling direction can be adapted and the effective pulling force increased. The rated load is determined by drum diameter, gear ratio, rope type, and the permissible housing load.
Areas of use in demolition, deconstruction, and extraction
The manual wire rope winch proves its value wherever loads must be moved, secured, or finely positioned in a controlled manner—often in concert with hydraulic tools from Darda GmbH.
Concrete demolition and special deconstruction
- Securing concrete elements before and during separating, for example when concrete demolition shear loosen individual component shells.
- Guiding and edging components during controlled lowering in tight building structures.
- Pre-positioning of units or accessories (e.g., hydraulic power units) on confined standings, provided it is structurally permissible and properly slung.
Building gutting and cutting
- Holding facing shells, lintels, or smaller slab segments until cuts are made and reinforcement is selectively severed.
- Pulling utility lines, debris chutes, or guide systems across multiple stories.
Rock breakout and tunnel construction
- Guiding loosened rock blocks after the use of hydraulic wedge splitter and concrete splitter in drifts and shafts.
- Hauling hose bundles and accessories in headings with limited ground clearance.
Natural stone extraction
- Securing raw blocks after the splitting process, aligning for gentle placement.
- Fine positioning of wedges, rails, or wooden beams as supports.
Special use
- Rescue pulls for jammed equipment when adequately load-bearing anchorage points are available.
- Temporary tensioning of auxiliary ropes as guide or restraint systems.
Selection criteria and sizing
When selecting a manual wire rope winch, the key factors are pulling force (permissible working load), rope length and drum capacity, type of brake, gearing (single- or two-stage), corrosion protection, and the options for mounting. For dust- and sludge-intensive operations such as those in concrete demolition or tunnel construction, a closed, maintenance-friendly design is advantageous. The rope must suit the drum (D/d ratio) and be appropriate for edge and reeving loads.
Estimating the required pulling force
The required pulling force depends on mass, friction, gradient, and any binding loads. To start loads moving, a higher initial pulling force is typically needed than for steady pulling. Snatch blocks can increase the effective pulling force; the resulting forces at anchorage points must be included in calculations. Safety factors must be planned; the permissible working load of the winch and all slinging gear must not be exceeded.
Operation and safety
Safe work with manual wire rope winches is based on proper mounting, correct slinging, and clear team communication, especially when working in parallel with concrete demolition shear, hydraulic shear, or hydraulic wedge splitter and concrete splitter.
- Preparations: Check the condition of the winch (brake, pawl, crank interface), inspect the rope for broken wires and kinks, use hooks with safety latches, document load capacities.
- Select anchorage points: Use only load-bearing, suitable components or certified anchorage points; protect edges; close and secure snatch blocks correctly.
- Guiding the load: Keep the load path clear, keep people away; never stand in line with the rope; work with signals and unambiguous commands.
- Cranking and holding: Smooth, even movements; verify the load-pressure brake; when lowering, always maintain secure control of the crank.
- Follow-up: Spool the rope neatly, remove contamination, document any damage.
Note: Interaction with hydraulic tools requires coordinated sequences to keep cutting, splitting, and pulling motions from interfering with one another.
Combination with rock and concrete splitters and concrete demolition shear
The manual wire rope winch complements hydraulic tools from Darda GmbH by adding control and stability when moving components. Typical applications include pre-tensioning, holding, and aligning sections before the actual separation or splitting takes place.
- Before splitting: Slightly pre-tension the raw block or component to stabilize the splitting direction; after the split, perform controlled lowering.
- In concrete crushing: Secure the component before the concrete demolition shear to avoid unwanted torque and uncontrolled movements.
- When cutting reinforcement with Multi Cutters or steel shear: Simultaneously hold the segment so that it can be guided down after the final cut.
- For special tasks: Assistance in recovering or relocating rock splitting cylinders and accessories, provided mass and anchorage points permit.
Accessories and slinging gear
Suitable slinging gear is indispensable for safe use: shackles, round slings, chains, edge protectors, hooks with safety latches, thimbles, and snatch blocks with appropriate capacity. The wire rope should have a construction matching the drum and be properly terminated with a swaged ferrule or comparable end fitting. Clear marking of load capacity facilitates job planning.
Maintenance and inspection
Regular cleaning and light lubrication of moving parts increase service life. The brake is checked for smooth holding; the pawl must engage cleanly. The wire rope must be replaced in case of strand breaks, crushing, corrosion, flared sections, or damaged terminations. Hooks must be withdrawn from service if there is spreading or evidence of cracks. Inspection intervals depend on the level of stress and applicable regulations; results should be documented.
Distinction and alternatives
Compared with cable pullers using clamping mechanisms, the manual wire rope winch offers neat rope take-up and smooth running, but is limited by drum capacity. Chain hoists are particularly suitable for vertical lifting, whereas manual wire rope winches excel at horizontal pulling and holding. Electric or hydraulic winches increase speed but require a power supply and additional protective measures. Regardless, the manual wire rope winch remains a precise, finely controllable aid that functionally complements work with hydraulic tools—such as concrete demolition shear, hydraulic wedge splitter and concrete splitter, as well as steel shear.
Practical example from the field
In an occupied building, a reinforced concrete lintel is selectively removed. First, the lintel is pre-tensioned on both sides with manual wire rope winches and slung with edge protection. The team then makes cuts and selectively severs the reinforcement. While a concrete demolition shear from Darda GmbH progressively crushes the lintel, the manual wire rope winches hold the component in position and enable guided lowering onto a prepared support. The result is a controlled deconstruction with minimal vibrations and without uncontrolled load movements.
Organizational and legal aspects
Manual wire rope winches may only be operated within their permissible working load and with suitable slinging gear. Selection, inspection, and use should be performed by trained personnel. Company instructions, markings, and regular inspections support safe application. The relevant regulations and the manufacturers’ specifications are authoritative; project-specific boundary conditions must be assessed on site.