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Torsion springs store massive amounts of energy and can cause severe injury or death if released uncontrollably
Torsion springs on overhead doors are wound under extreme tension, storing enough energy to lift hundreds of pounds. An uncontrolled release can launch tools or hardware at lethal velocity, or cause the winding bar to spin violently. It can come from a slipping winding bar, a broken cone, or an improper procedure. This is the single most dangerous hazard in the overhead door trade and has caused numerous fatalities.
Always use proper winding bars
Use hardened steel winding bars that are the correct diameter for the winding cone (typically 1/2"). NEVER substitute screwdrivers, rebar, or other improvised tools. They can slip out of the cone and become projectiles.
Maintain two-bar contact at all times
Always keep one winding bar firmly seated in the cone while repositioning the other. Never have fewer than one bar engaged during winding or unwinding.
Secure the door before spring work
Clamp the door to the track with locking pliers or C-clamps in the fully closed position before removing, adjusting, or replacing springs. This prevents the door from moving if spring tension is lost.
Stand to the side of the winding cone
Position your body to the side of the cone, never directly in line with the winding bars. If a bar slips, it will travel in the plane of the spring. Standing offset keeps you out of the strike zone.
Inspect cones and set screws before work
Check winding cones for cracks, worn set screw holes, and stripped threads before applying tension. Replace any suspect components. Use hardened set screws rated for the application.
Use the correct spring for the door weight
Use a spring calculator to match the spring wire size, inside diameter, and length to the door weight and height. An undersized spring requires more turns and operates closer to its stress limit.