Winter and Hydrovacs: Cold Weather Tips For Safe Excavation

Winter is coming.

Cold, snowy days sound cozy when you're inside with a blanket and a hot cup of coffee. But if you're running hydrovac equipment, it’s time to brace yourself. 

Excavating in freezing temps? You already know how fast things can go sideways. It’s the kind of annoying that keeps you doomscrolling for a solution at 2 AM. The good news? With the proper preparation and a solid understanding of how cold weather affects hydrovac performance, you can keep your crew moving briskly in the winter months. 

The cold, your greatest foe

Enter public enemy number one: the cold. 

Hydrovac trucks rely on heated, pressurized water to break up soil, and if that water supply freezes, you'll be putting up your 'closed' sign on the window because you’ll be out of business for the day. Cold temps can lead to frozen water lines, pump damage, and cracked tanks, especially if your system doesn’t have built-in winterization features.

Even a brief overnight freeze can block your nozzles, especially in spray nozzles or debris tanks that aren’t fully cleared, or harden leftover sludge in the tank. If water isn’t appropriately drained or heating elements aren’t functioning properly, you’re looking at downtime or, worse, damage to the equipment (a nightmare).

What helps is a combination of heated tanks, circulating water systems, hose reels with heat tracing, and onboard boilers that keep temperatures high enough to stay operational, even in extreme cold. So, when the cold weather drifts in, make sure you're beating the cold with enough heat.

The ground does not yield

Anyone who has dug a post hole in January knows that frozen ground can be a real challenge to work with. It’s like trying to dig through ice cream from the freezer when all you want are the chocolate chip chunks beneath the surface. 

Hydrovac trucks  rely on pressurized water to soften soil, and winter ground conditions often require even higher temperatures and pressure to get the same results. In colder zones, you’re not just digging through dirt; you’re working against frost layers that can be inches deep (like that ice cream).

Picking a truck with a strong boiler system matters when you’re working in places where the ground freezes up into ice. Some models can push water temps past 180°F, giving you the power to break through frozen clay or packed gravel without slowing the job down.

Spoils of ice and trouble

Let’s say you’ve successfully excavated a trench, but now you’re stuck with a load of frozen sludge in your debris tank. That stuff is heavy, sticky, and stubborn–the worst. 

If the tank or valves freeze before you can dump the contents, you’re hauling around literal tons of frozen water. A full debris tank can weigh 8,000 to 10,000 pounds or more, with no easy way to dispose of it. This creates problems fast. 

Full tanks cut job time short, frozen valves jam up your system, and heavy buildup can strain your hydraulics. You also don’t want to be that crew at the disposal site fighting with frozen spoils while the clock keeps ticking. Dumping more frequently during winter helps. Similarly, using heated valves, tank jackets, and scheduling disposal stops closer to the site can also be beneficial. Some crews even add de-icing agents where permitted to keep things flowing.

Engines need winter armor 

No one rides into winter unscathed, not even your engine. 

Cold weather can cause slow starts, reduced engine efficiency, and battery drain. Though vital in construction for the extra power they provide trucks of all types, diesel engines, in particular, can struggle with fuel gelling or sluggish injectors once temperatures drop.

Luckily, many hydrovac trucks are built with cold-weather engine packages. These often include block heaters, fuel warmers, and oil pan heaters designed to help equipment fire up reliably on freezing mornings. Long warm-up times don’t just cost time; they cost fuel, and both time and fuel are money. That adds up quickly if you're on multiple jobs a week.

Cold conditions raise the stakes

Cold weather adds layers of risk, not just mechanical, but for those behind the wheel. Slippery conditions, icy steps, and reduced visibility all increase the likelihood of job-site injuries. Winter gear can also limit mobility, making it harder to move around.

Crew safety is as essential as truck safety. Make sure your team has the tools for the job:

• Non-slip boots and insulated gloves rated for sub-zero temps
• Exterior steps, platforms, and handrails with anti-slip coatings
• Proper winter visibility markers, including heated mirrors or backup cameras
• Fire extinguishers and shutoff valves for quick access in emergencies

Fortify your fleet 

If you’re not already winterizing your truck, now’s the time; it’s better to get ahead on planning than to fall behind and get left in the cold. A winter-ready hydrovac isn’t just about comfort; it’s about protecting your investment and staying on schedule when the mercury drops.

First, you start by draining your water tanks and lines at the end of each shift. Run all heating systems before and during operation to ensure optimal performance. Store trucks in heated bays or use tank warmers overnight if left outside. Add diesel anti-gel additives regularly. And even if your truck isn’t on a job, keep systems running periodically to prevent freeze damage.

If your truck isn’t ready for winter, you can still make it work. Things like adding heated lines, insulation, or a more robust boiler system can help keep it running longer during cold weather and reduce lost time.

Ready for the winter battle?

Come and check out our lineup of winter-ready hydrovac trucks at Summit Truck Equipment. We’ve got the solutions to keep you digging year-round. If you’re planning to invest in a new truck, be sure to explore our hydrovac financing guide for payment plans that match your seasonal needs.