12 Aug Concrete Cutting / Drilling – JSA

Concrete Cutting / Drilling Safety Analysis (JSA)

Job / Task

Saw cutting, core drilling, hammer drilling, rotary drilling, wall or slab cutting, and related penetration of concrete or masonry using electric, pneumatic, hydraulic, or engine-powered equipment.

Purpose

This Job Safety Analysis (JSA), also known as a Job Hazard Analysis (JHA), identifies hazards associated with concrete cutting and drilling and establishes controls to prevent respirable crystalline silica exposure, blade or bit contact, kickback, electrical shock, utility strikes, falls, flying debris, noise, vibration, and injuries from falling or released concrete.

Personnel Qualifications

Concrete cutting and drilling shall be performed only by employees trained in the equipment, manufacturer instructions, applicable silica controls, utility-identification procedures, and task-specific hazards. Specialized saws, core drills, and powered equipment shall be used only by trained and authorized personnel.

Employees shall:

• Understand the planned cut or penetration, equipment limitations, and required engineering controls.
• Verify the work area for concealed utilities, reinforcing steel, post-tensioning systems, and structural hazards before cutting or drilling.
• Inspect saws, drills, blades, bits, guards, cords, hoses, water systems, and attachments before use.
• Use required silica-control methods and PPE.
• Keep body parts clear of blades, bits, rotating components, and the line of fire.
• Maintain stable footing and control equipment during startup and operation.
• Stop work if the equipment binds, kicks back, loses water or dust control, or encounters an unexpected obstruction.

Required PPE

PPE shall be selected based on the task and exposure assessment and may include:

• Hard hat.
• Safety glasses with side protection.
• Face shield where flying fragments or splash hazards warrant additional protection.
• Safety footwear.
• Work gloves appropriate for handling equipment and concrete materials.
• Hearing protection.
• High-visibility apparel where exposed to traffic or mobile equipment.
• Respiratory protection when required by the silica exposure assessment and respiratory-protection program.
• Fall-protection equipment where required.
• Waterproof or chemical-resistant protection where prolonged wet work creates skin exposure.
• Additional task-specific PPE identified by the hazard assessment.

JSA – Job Steps, Hazards, and Controls

Step 1 – Plan the Cut or Penetration

Potential Hazards

• Structural damage.
• Utility strike.
• Uncontrolled falling concrete.

Required Controls

• Review drawings, specifications, and the purpose, size, depth, and location of the cut or hole.
• Determine whether the concrete is structural and whether engineering approval is required before penetration.
• Identify work occurring above, below, and on the opposite side of the surface.
• Plan silica controls, water management, debris containment, and exclusion zones.
• Determine how cut sections or cores will be supported and removed.

Step 2 – Identify Concealed Hazards

Potential Hazards

• Electrocution.
• Gas or water release.
• Post-tension tendon strike.
• Structural damage.

Required Controls

• Review available drawings and utility information.
• Use appropriate scanning, locating, or other detection methods where concealed hazards may be present.
• Identify electrical conduit, piping, reinforcing steel, embedded objects, and post-tensioning systems.
• Do not cut or drill through post-tensioned concrete unless the tendon locations are positively identified and the work is specifically authorized.
• Stop work if concealed conditions cannot be adequately determined.

Step 3 – Establish the Work Zone

Potential Hazards

• Struck-by.
• Public exposure.
• Flying debris.
• Falling core or cut section.

Required Controls

• Barricade or control the cutting and drilling area.
• Protect personnel on the opposite side and below the work surface.
• Establish an exclusion zone for falling cores, slurry, debris, and equipment movement.
• Redirect pedestrians and other workers as necessary.
• Provide adequate lighting.

Step 4 – Inspect the Equipment

Potential Hazards

• Blade or bit failure.
• Electrical shock.
• Unexpected startup.

Required Controls

• Inspect the saw or drill before use.
• Verify guards, handles, switches, triggers, emergency controls, and safety devices function properly.
• Inspect blades and bits for damage, wear, cracks, missing segments, or incorrect specifications.
• Check cords, plugs, hoses, fittings, water connections, and vacuum systems.
• Remove defective equipment from service.

Step 5 – Select the Correct Blade / Bit

Potential Hazards

• Blade failure.
• Kickback.
• Poor equipment control.

Required Controls

• Use blades and bits designed for the equipment, material, diameter, speed, and cutting method.
• Verify the accessory’s rated speed is compatible with the equipment.
• Install accessories according to manufacturer instructions.
• Disconnect or isolate the power source before installation or adjustment.
• Do not use damaged, modified, or incompatible accessories.

Step 6 – Set Up Silica Controls

Potential Hazards

• Respirable crystalline silica exposure.
• Reduced visibility.

Required Controls

• Use wet cutting, integrated water delivery, local exhaust, or other engineering controls appropriate to the equipment and task.
• Ensure water reaches the blade or bit at the point of dust generation when wet methods are used.
• Use dust-collection equipment with appropriate filtration when required.
• Follow applicable OSHA silica-control requirements and exposure-assessment procedures.
• Stop work if required engineering controls fail.

Step 7 – Set Up Electrical Equipment

Potential Hazards

• Electrical shock.
• Electrocution.
• Damaged cords in wet conditions.

Required Controls

• Inspect electrical cords, plugs, connectors, and equipment before use.
• Use required GFCI protection.
• Keep electrical connections out of standing water and protect them from slurry.
• Route cords to prevent damage and trip hazards.
• Do not use electrical equipment with damaged insulation, missing grounding components, or other electrical defects.

Step 8 – Set Up Pneumatic / Hydraulic Equipment

Potential Hazards

• Hose whip.
• Injection injury.
• Unexpected release of pressure.

Required Controls

• Inspect hoses, couplings, fittings, and retaining devices.
• Secure connections before pressurizing.
• Protect hoses from traffic, sharp edges, and crushing.
• Relieve pressure before disconnecting or servicing lines.
• Never use bare hands to locate suspected hydraulic leaks.

Step 9 – Position and Secure the Workpiece / Surface

Potential Hazards

• Movement of concrete section.
• Pinch point.
• Falling material.

Required Controls

• Determine whether the cut will release a slab, wall section, core, or other material.
• Support or rig sections before completing cuts when uncontrolled movement is possible.
• Keep employees clear of the expected fall or swing path.
• Do not rely on the blade or bit to support a cut section.
• Use qualified rigging methods for heavy components.

Step 10 – Mount / Anchor a Core Drill

Potential Hazards

• Drill movement.
• Entanglement.
• Falling equipment.

Required Controls

• Secure the drill stand using an approved anchor, vacuum base, or manufacturer-approved method.
• Verify the mounting surface is suitable.
• Do not rely on an unsecured drill stand.
• Use supplemental fall restraint or securing methods for elevated equipment where necessary.
• Keep the work area clear of the rotating spindle and bit.

Step 11 – Begin Saw Cutting

Potential Hazards

• Kickback.
• Blade contact.
• Flying debris.
• Noise.

Required Controls

• Maintain a stable stance and firm control of the saw.
• Allow the blade to reach operating speed before entering the cut when required by the manufacturer.
• Keep the blade guard in the proper position.
• Do not force, twist, pinch, or side-load the blade.
• Keep personnel out of the blade plane and discharge path.

Step 12 – Perform Floor / Slab Sawing

Potential Hazards

• Loss of control.
• Blade contact.
• Trip hazard.
• Slurry.

Required Controls

• Inspect the travel path before cutting.
• Maintain controlled forward movement and follow manufacturer operating procedures.
• Keep hands and feet away from the blade.
• Manage water, slurry, cords, and hoses to prevent slips and trips.
• Do not leave a running saw unattended.

Step 13 – Perform Hand-Held Saw Cutting

Potential Hazards

• Kickback.
• Loss of balance.
• Blade contact.

Required Controls

• Use two-handed control when the equipment is designed for it.
• Maintain balanced footing and avoid overreaching.
• Do not cut above shoulder height unless the equipment and procedure are specifically suitable for that use.
• Position the body out of the anticipated kickback path.
• Allow the blade to stop before setting the tool down.

Step 14 – Perform Wall Sawing

Potential Hazards

• Falling concrete.
• Equipment detachment.
• Working-at-height hazard.

Required Controls

• Secure rails and equipment according to manufacturer instructions.
• Verify the wall and anchorage can support the equipment.
• Establish exclusion zones on both sides of the wall.
• Support sections that could fall when the cut is completed.
• Use required fall protection for elevated work.

Step 15 – Perform Core Drilling

Potential Hazards

• Bit binding.
• Drill rotation.
• Falling core.
• Water leakage.

Required Controls

• Secure the drill before operation.
• Feed the bit gradually and avoid excessive pressure.
• Keep hands, clothing, and cords clear of rotating parts.
• Protect personnel below and on the opposite side of the penetration.
• Capture or control the core before it can fall.

Step 16 – Perform Hammer / Rotary Drilling

Potential Hazards

• Silica exposure.
• Flying particles.
• Vibration.
• Bit binding.

Required Controls

• Use integrated dust collection or wet methods as applicable.
• Maintain stable footing and two-handed control where designed.
• Use the correct bit and avoid excessive force.
• Keep the drill aligned with the intended hole.
• Stop if the bit binds or an unexpected embedded object is encountered.

Step 17 – Work Near Reinforcing Steel

Potential Hazards

• Bit or blade binding.
• Kickback.
• Unexpected cutting resistance.

Required Controls

• Identify reinforcing steel where practical before cutting or drilling.
• Use equipment and accessories suitable for reinforced concrete.
• Reduce feed pressure when changing material conditions are encountered.
• Do not force a blade or bit through an obstruction.
• Stop and reassess when resistance indicates an unidentified embedded item.

Step 18 – Manage Water and Slurry

Potential Hazards

• Slip hazard.
• Electrical hazard.
• Environmental release.

Required Controls

• Collect or direct slurry away from walking surfaces and electrical equipment.
• Use berms, wet vacuums, containers, or other controls as appropriate.
• Do not discharge concrete slurry into storm drains or waterways unless specifically permitted.
• Maintain housekeeping throughout the task.
• Clean slurry before it dries and becomes airborne dust.

Step 19 – Cut or Drill Overhead

Potential Hazards

• Falling debris.
• Shoulder strain.
• Eye and face exposure.

Required Controls

• Avoid overhead cutting or drilling when a safer method is available.
• Establish an exclusion zone beneath the work.
• Use equipment designed for the orientation.
• Provide eye, face, and respiratory protection as required.
• Use work platforms or access equipment that allow stable positioning rather than overreaching.

Step 20 – Work at Heights

Potential Hazards

• Fall from elevation.
• Dropped equipment.

Required Controls

• Use approved ladders, scaffolds, aerial lifts, or work platforms appropriate to the task.
• Provide fall protection where required.
• Secure equipment and materials against falling.
• Do not perform high-force cutting or drilling from an unstable ladder position.
• Keep access equipment outside unsafe debris zones.

Step 21 – Control Noise and Vibration

Potential Hazards

• Hearing loss.
• Hand-arm vibration.
• Fatigue.

Required Controls

• Use hearing protection where required by noise exposure.
• Maintain tools and use sharp, appropriate blades and bits.
• Limit unnecessary exposure to vibrating tools.
• Rotate tasks or provide breaks where appropriate.
• Report unusual numbness, tingling, or equipment vibration.

Step 22 – Clear a Bound Blade / Bit

Potential Hazards

• Unexpected movement.
• Laceration.
• Stored energy.

Required Controls

• Release the trigger and allow equipment to stop.
• Disconnect, unplug, or otherwise isolate the energy source before attempting to free the accessory.
• Support any concrete section that may shift.
• Do not pull or twist energized equipment to free a jam.
• Inspect the blade, bit, and equipment before restarting.

Step 23 – Complete Through-Cuts

Potential Hazards

• Sudden release of concrete.
• Falling section.
• Pinch/crush injury.

Required Controls

• Confirm the section is supported before completing the final cut.
• Keep personnel out of the drop and swing zone.
• Use rigging or mechanical handling for heavy sections.
• Complete the cut in the planned sequence.
• Do not stand beneath or downhill from released material.

Step 24 – Remove Cores and Cut Sections

Potential Hazards

• Crushing.
• Manual-handling strain.
• Sharp edges.

Required Controls

• Determine the weight before manual handling.
• Use lifting devices, carts, team lifting, or mechanical equipment for heavy sections.
• Wear gloves when handling sharp concrete edges.
• Keep hands clear of pinch points.
• Store or remove sections so they cannot roll or fall.

Step 25 – Shut Down Equipment

Potential Hazards

• Unexpected startup.
• Burns.
• Blade contact.

Required Controls

• Turn off and isolate the power source.
• Allow blades, bits, and equipment to stop completely.
• Allow hot components to cool before handling.
• Relieve pneumatic or hydraulic pressure where applicable.
• Do not leave equipment energized while unattended.

Step 26 – Change Blades / Bits

Potential Hazards

• Cuts.
• Unexpected startup.
• Improper installation.

Required Controls

• Disconnect or isolate all energy before changing accessories.
• Wear gloves as appropriate for sharp accessories.
• Inspect the replacement blade or bit before installation.
• Install and tighten components according to manufacturer instructions.
• Reinstall and adjust guards before operation.

Step 27 – Clean the Work Area

Potential Hazards

• Silica exposure.
• Trips.
• Cuts.

Required Controls

• Use wet cleanup or HEPA-filtered vacuuming where silica-containing dust is present.
• Do not dry sweep or use compressed air where it would create hazardous silica exposure unless permitted with effective controls.
• Remove concrete fragments, slurry, cords, hoses, and tools.
• Dispose of slurry and debris in designated locations.
• Leave walking and work surfaces safe and unobstructed.

General Safe Work Requirements

• Concrete cutting and drilling shall be performed only by trained employees using equipment suitable for the task.
• The location of concealed utilities, embedded objects, reinforcing steel, and post-tensioning systems shall be evaluated before penetration.
• Post-tensioning tendons shall not be cut, drilled, or disturbed without positive identification, authorization, and appropriate controls.
• Required engineering controls shall be used to minimize respirable crystalline silica exposure.
• Water-delivery or dust-collection systems shall be maintained in effective operating condition during work.
• Guards and manufacturer-provided safety devices shall remain installed and functional.
• Blades and bits shall be compatible with the equipment, material, speed, and intended use.
• Equipment shall be de-energized before blade or bit changes, jam clearing, adjustment, or servicing.
• Required GFCI protection shall be used for applicable electrical equipment, particularly where water is present.
• Employees shall remain outside blade planes, kickback paths, falling-object zones, and other lines of fire.
• Concrete cores and cut sections shall be supported or controlled before completing cuts where falling or shifting is possible.
• Personnel below or on the opposite side of a penetration shall be protected from falling cores, debris, and equipment.
• Slurry shall be controlled to prevent slips, electrical hazards, and uncontrolled environmental discharge.
• Required fall protection shall be used for elevated cutting and drilling work.
• Defective tools, guards, cords, hoses, blades, bits, or safety systems shall be removed from service.
• Work shall stop when concealed hazards, equipment condition, silica controls, structural conditions, or other safeguards are uncertain or inadequate.

Training

Employees performing concrete cutting and drilling shall receive training appropriate to their assigned duties. Training shall address equipment operation, blade and bit selection, guarding, kickback and binding, respirable crystalline silica hazards and controls, concealed utilities, reinforcing steel and post-tensioning awareness, electrical and GFCI requirements, water and slurry management, falling-core hazards, work at heights, noise, vibration, PPE, energy isolation, and emergency procedures. Employees using specialized saws, core-drilling systems, or powered access equipment shall receive additional training and authorization as required.

References

• OSHA 29 CFR 1926.1153 – Respirable Crystalline Silica.
• OSHA 29 CFR 1926 Subpart I – Tools – Hand and Power.
• OSHA 29 CFR 1926 Subpart K – Electrical.
• OSHA 29 CFR 1926 Subpart M – Fall Protection, where applicable.
• OSHA 29 CFR 1926 Subpart Q – Concrete and Masonry Construction, where applicable.
• Applicable manufacturer instructions, engineering requirements, site procedures, and client requirements.