12 Aug Concrete Work – JSA

Concrete Work Safety Analysis (JSA)

Job / Task

Preparation, formwork, reinforcing steel, mixing, pumping, placing, screeding, finishing, curing, cutting, drilling, chipping, and cleanup associated with concrete construction and repair.

Purpose

This Job Safety Analysis (JSA), also known as a Job Hazard Analysis (JHA), identifies hazards associated with concrete work and establishes controls to prevent chemical burns, silica exposure, struck-by and caught-between injuries, falls, impalement, equipment incidents, hose-whip injuries, electrical contact, and musculoskeletal injuries.

Personnel Qualifications

Concrete work shall be performed by trained employees familiar with the tools, equipment, materials, and hazards involved. Specialized equipment such as concrete pumps, saws, powered finishing equipment, and lifting devices shall be operated only by trained and authorized personnel.

Employees shall:

• Understand the work plan, concrete placement sequence, access routes, and exclusion zones.
• Recognize hazards from wet concrete, cement dust, silica, reinforcing steel, formwork, equipment, and pressurized delivery systems.
• Inspect tools and equipment before use and report defects.
• Use required PPE and immediately wash wet concrete or cement from the skin.
• Remain clear of suspended loads, concrete buckets, pump booms, pinch points, and moving equipment.
• Follow fall-protection, electrical-safety, silica-control, and energy-control procedures as applicable.
• Stop work when conditions, equipment, formwork, access, or other safeguards become unsafe.

Required PPE

PPE shall be selected based on the specific concrete activity and exposure assessment and may include:

• Hard hat.
• Safety glasses with side protection; goggles or face shield where splash or flying-particle hazards exist.
• Safety footwear, including waterproof boots where contact with wet concrete is possible.
• Alkali-resistant or waterproof gloves suitable for wet concrete.
• Long sleeves and long pants to minimize skin exposure to cement and wet concrete.
• High-visibility apparel where exposed to vehicles or mobile equipment.
• Hearing protection where required.
• Respiratory protection when required by the exposure assessment and respiratory-protection program.
• Fall-protection equipment where required.
• Additional task-specific PPE identified by the hazard assessment.

JSA – Job Steps, Hazards, and Controls

Step 1 – Plan the Concrete Work

Potential Hazards

• Poor coordination.
• Equipment conflict.
• Uncontrolled exposures.

Required Controls

• Review the scope, placement method, concrete quantity, access, equipment, manpower, and sequence.
• Identify overhead and underground utilities, traffic, pedestrians, excavations, open edges, and other site hazards.
• Determine pump, truck, crane, washout, material-storage, and emergency locations.
• Establish exclusion zones and communication methods.
• Review weather conditions that could affect placement, finishing, curing, or worker exposure.

Step 2 – Inspect the Work Area

Potential Hazards

• Trips and falls.
• Unstable ground.
• Vehicle or equipment incident.

Required Controls

• Remove unnecessary debris and obstructions.
• Verify access routes and working surfaces are stable and suitable for employees and equipment.
• Protect floor openings, edges, excavations, and other fall hazards.
• Provide adequate lighting.
• Maintain separation between pedestrians and mobile equipment where practical.

Step 3 – Receive and Store Materials

Potential Hazards

• Struck-by.
• Crushing.
• Manual-handling injury.

Required Controls

• Use appropriate mechanical equipment for heavy materials.
• Store forms, lumber, reinforcing steel, bags, and other materials on stable surfaces.
• Secure materials against rolling, shifting, or falling.
• Keep access and emergency routes clear.
• Use team lifting or mechanical assistance for heavy or awkward items.

Step 4 – Construct and Inspect Formwork

Potential Hazards

• Formwork collapse.
• Falls.
• Nail punctures.
• Caught-between injury.

Required Controls

• Construct formwork to safely support anticipated vertical and lateral loads.
• Inspect forms, shores, braces, ties, and supports before concrete placement.
• Do not use damaged or inadequately supported formwork.
• Remove or bend protruding nails when practical.
• Provide safe access and fall protection where required.

Step 5 – Install Reinforcing Steel

Potential Hazards

• Impalement.
• Cuts.
• Strains.
• Falls.

Required Controls

• Protect exposed reinforcing steel that employees could fall onto or against using approved impalement protection.
• Use gloves when handling reinforcing steel.
• Use mechanical assistance for heavy bundles or assemblies.
• Secure reinforcing steel to prevent displacement.
• Maintain safe access around reinforcing assemblies.

Step 6 – Handle Bagged Cement / Dry Concrete Products

Potential Hazards

• Cement dust.
• Eye irritation.
• Skin irritation.
• Manual-handling injury.

Required Controls

• Minimize dust generation when opening and emptying bags.
• Avoid pouring or dumping dry material from excessive height.
• Use required eye and respiratory protection based on the exposure assessment.
• Use proper lifting techniques or mechanical assistance.
• Wash exposed skin promptly and avoid contaminated clothing remaining against the skin.

Step 7 – Mix Concrete On Site

Potential Hazards

• Caught-in machinery.
• Dust.
• Electrical shock.
• Chemical burns.

Required Controls

• Inspect mixers, guards, cords, grounding, and controls before use.
• Keep hands, tools, and clothing away from moving mixer components.
• Do not reach into or clean a mixer while it is energized.
• Control cement dust during charging.
• Use GFCI protection for applicable electrical equipment in wet locations.

Step 8 – Position Ready-Mix Trucks

Potential Hazards

• Backing incident.
• Run-over.
• Collision.
• Unstable ground.

Required Controls

• Establish a controlled truck route and placement area.
• Use a spotter when visibility is restricted or site conditions require one.
• Keep personnel out of the truck’s backing path and blind spots.
• Verify ground can support the loaded truck.
• Maintain safe clearance from excavation edges, overhead power lines, and structures.

Step 9 – Set Up the Concrete Pump

Potential Hazards

• Pump rollover.
• Overhead electrical contact.
• Crushing.
• Hose failure.

Required Controls

• Set up the pump on firm, stable ground in accordance with manufacturer requirements.
• Fully deploy outriggers or stabilizers as required and use appropriate pads.
• Verify overhead clearance and maintain required clearance from energized power lines.
• Establish an exclusion zone around outriggers and the pump.
• Inspect boom, pipeline, clamps, hoses, safety devices, and controls before pumping.

Step 10 – Connect Pump Lines and Hoses

Potential Hazards

• Pinch points.
• Hose separation.
• Concrete release.

Required Controls

• Use compatible pipe, hose, clamps, gaskets, and safety devices.
• Inspect components for wear, cracks, damage, or contamination.
• Secure connections before pressurizing.
• Keep personnel clear of line connections during startup.
• Do not use damaged or improperly rated components.

Step 11 – Prime and Start the Pump

Potential Hazards

• Hose whip.
• Pressurized concrete discharge.
• Struck-by injury.

Required Controls

• Clear unnecessary personnel from the discharge area.
• Control the end hose before pumping begins.
• Increase pressure gradually.
• Maintain communication between the pump operator and placement crew.
• Stop pumping immediately if abnormal movement, blockage, leakage, or equipment malfunction occurs.

Step 12 – Place Concrete by Pump Hose

Potential Hazards

• Hose whip.
• Strains.
• Wet-concrete exposure.
• Slip hazard.

Required Controls

• Maintain control of the hose using sufficient personnel or mechanical assistance.
• Keep the hose away from the body and do not straddle it.
• Avoid sharp bends or kinks.
• Maintain stable footing and keep walking surfaces as clean as practical.
• Wear waterproof gloves, boots, and protective clothing when contact with wet concrete is possible.

Step 13 – Clear a Pump-Line Blockage

Potential Hazards

• Sudden pressure release.
• Hose whip.
• Projectile hazard.

Required Controls

• Stop the pump and relieve pressure before disconnecting any line or clamp.
• Follow manufacturer procedures for clearing blockages.
• Keep personnel out of the line of fire.
• Never strike, open, or disconnect a pressurized line.
• Only trained and authorized personnel shall clear blockages.

Step 14 – Place Concrete by Bucket

Potential Hazards

• Suspended load.
• Crushing.
• Concrete discharge.

Required Controls

• Inspect the bucket and rigging before use.
• Keep employees clear of suspended buckets.
• Do not ride concrete buckets.
• Control the bucket with tag lines where appropriate and safe.
• Position employees clear of pinch points and the discharge gate.

Step 15 – Place Concrete from Chutes

Potential Hazards

• Struck-by.
• Pinch points.
• Wet-concrete splash.

Required Controls

• Secure chutes before use.
• Keep hands clear of chute hinges and pinch points.
• Do not stand beneath unsupported chute sections.
• Control chute movement during repositioning.
• Maintain stable footing around the discharge area.

Step 16 – Spread and Screed Concrete

Potential Hazards

• Overexertion.
• Slips.
• Wet-concrete contact.

Required Controls

• Use tools with suitable handles and maintain balanced posture.
• Rotate demanding tasks where practical.
• Avoid prolonged kneeling or standing in wet concrete.
• Use knee protection or waterproof protection where kneeling is necessary.
• Wash wet concrete from skin immediately.

Step 17 – Vibrate Concrete

Potential Hazards

• Electrical shock.
• Noise.
• Vibration exposure.
• Trips.

Required Controls

• Inspect vibrators, cords, hoses, and controls before use.
• Use GFCI protection for applicable electric vibrators.
• Keep cords and hoses organized to reduce trip hazards.
• Use hearing protection where required.
• Limit unnecessary hand-arm vibration exposure.

Step 18 – Perform Power Screeding

Potential Hazards

• Moving parts.
• Noise.
• Strains.
• Loss of control.

Required Controls

• Use trained operators.
• Inspect guards, handles, controls, and power sources before use.
• Keep hands and feet clear of moving components.
• Maintain stable footing and adequate clearance from edges.
• Shut down equipment before adjustment or cleaning.

Step 19 – Perform Power Troweling

Potential Hazards

• Contact with rotating blades.
• Carbon monoxide.
• Noise.
• Slips.

Required Controls

• Use trained and authorized operators.
• Inspect guards and controls before use.
• Keep personnel clear of rotating equipment.
• Do not use gasoline-powered equipment in enclosed or inadequately ventilated spaces without appropriate controls.
• Shut down and isolate equipment before servicing or clearing obstructions.

Step 20 – Hand Finish Concrete

Potential Hazards

• Chemical burns.
• Knee injury.
• Ergonomic strain.

Required Controls

• Wear waterproof gloves and appropriate skin protection.
• Avoid direct skin contact with wet concrete.
• Use knee pads or kneeling boards where appropriate.
• Change position periodically and use ergonomically suitable tools.
• Wash contaminated skin promptly with clean water and soap where available.

Step 21 – Work on Elevated Slabs or Edges

Potential Hazards

• Fall from elevation.
• Dropped tools or materials.

Required Controls

• Provide required guardrails, personal fall-arrest systems, or other fall protection.
• Protect floor and wall openings.
• Keep materials back from unprotected edges.
• Use controlled access zones only where specifically permitted by applicable requirements.
• Protect personnel below from falling objects.

Step 22 – Work Around Vertical Reinforcing Steel

Potential Hazards

• Impalement.
• Cuts.
• Trip hazard.

Required Controls

• Guard exposed rebar or other projections where impalement hazards exist.
• Maintain clear access routes.
• Do not use rebar caps that provide only scratch protection where impalement protection is required.
• Remove unnecessary protrusions when practical.
• Keep employees from climbing reinforcing steel unless an approved access method is provided.

Step 23 – Cure Concrete / Apply Curing Compounds

Potential Hazards

• Chemical exposure.
• Slips.
• Fire hazard.

Required Controls

• Review the product safety information before use.
• Use required gloves, eye protection, ventilation, and respiratory protection.
• Control ignition sources when using flammable products.
• Restrict access to freshly treated surfaces.
• Clean spills promptly.

Step 24 – Saw-Cut Concrete

Potential Hazards

• Respirable crystalline silica.
• Blade contact.
• Flying particles.
• Noise.

Required Controls

• Use saws equipped with required guards and appropriate blades.
• Use wet cutting or other effective engineering controls for silica exposure.
• Keep hands and body clear of the blade path.
• Use eye, face, and hearing protection as required.
• Do not force or twist the blade in the cut.

Step 25 – Drill or Core Concrete

Potential Hazards

• Silica exposure.
• Entanglement.
• Electrical or utility contact.

Required Controls

• Verify the drilling location is clear of concealed electrical, plumbing, post-tensioning, and other hazards.
• Use wet methods or local exhaust as required for silica control.
• Secure the drill or core rig as required.
• Keep loose clothing and hands away from rotating components.
• Use GFCI protection for applicable electrical equipment.

Step 26 – Chip / Break Concrete

Potential Hazards

• Silica dust.
• Flying debris.
• Noise.
• Vibration.

Required Controls

• Use engineering controls such as water or local exhaust where applicable.
• Wear eye, face, hearing, and respiratory protection as required.
• Inspect pneumatic or electric tools before use.
• Maintain adequate spacing between workers.
• Control prolonged vibration exposure and rotate tasks where practical.

Step 27 – Work Around Post-Tensioned Concrete

Potential Hazards

• Stored-energy release.
• Projectile hazard.
• Structural damage.

Required Controls

• Identify post-tensioned slabs, tendons, and anchorage locations before drilling, cutting, coring, or demolition.
• Do not cut, drill, or disturb tendons without authorization and an approved procedure.
• Use scanning or other locating methods where required.
• Establish exclusion zones for stressing or detensioning activities.
• Use qualified personnel for post-tensioning work.

Step 28 – Strip Forms and Shores

Potential Hazards

• Falling material.
• Collapse.
• Nail punctures.

Required Controls

• Remove forms and shores only when concrete has achieved adequate strength and removal is authorized.
• Follow the planned stripping sequence.
• Keep personnel clear of falling formwork.
• Use mechanical assistance for heavy components.
• Remove or protect protruding nails and stack stripped materials safely.

Step 29 – Wash Out Concrete Equipment

Potential Hazards

• Chemical burns.
• Splash.
• Environmental release.

Required Controls

• Use designated concrete washout areas.
• Wear waterproof gloves, boots, and eye/face protection as needed.
• Prevent wash water from entering storm drains, waterways, or uncontrolled soil areas.
• Relieve pressure before cleaning pump lines or equipment.
• Keep washout areas barricaded or controlled as necessary.

Step 30 – Clean Up the Work Area

Potential Hazards

• Trips.
• Cuts.
• Silica dust.
• Chemical exposure.

Required Controls

• Remove concrete debris, tie wire, lumber, nails, and other waste regularly.
• Use wet methods or HEPA-filtered vacuuming where dry cleanup could create silica exposure.
• Do not dry sweep or use compressed air where it would create hazardous silica dust unless permitted with effective controls.
• Dispose of concrete and contaminated materials in designated locations.
• Leave access routes and walking surfaces clean and safe.

General Safe Work Requirements

• Concrete formwork, shoring, and bracing shall be capable of supporting anticipated loads and shall be inspected before placement.
• Employees shall be protected from exposed reinforcing steel and other projections that present impalement hazards.
• Direct skin contact with wet concrete and cement shall be minimized; contaminated skin and clothing shall be addressed promptly.
• Required engineering controls shall be used for respirable crystalline silica during cutting, drilling, grinding, chipping, and similar activities.
• Concrete pump systems, hoses, clamps, and connections shall be inspected and properly secured before pressurization.
• Pressurized concrete lines shall not be opened, disconnected, or serviced until pressure has been relieved.
• Employees shall remain clear of suspended concrete buckets, pump booms, mobile equipment, and other struck-by hazards.
• Ready-mix trucks and mobile equipment shall be controlled with designated routes and spotters where visibility is restricted.
• Applicable clearance from overhead electrical lines shall be maintained for pump booms, cranes, trucks, and other equipment.
• Fall protection shall be provided where employees are exposed to unprotected edges, openings, elevated work surfaces, or other qualifying fall hazards.
• Tools and equipment shall be inspected before use and defective items removed from service.
• Electrical equipment used in wet locations shall have appropriate grounding and GFCI protection as required.
• Post-tensioning tendons shall not be cut, drilled, or disturbed without proper identification, authorization, and controls.
• Concrete washout and waste shall be managed to prevent uncontrolled environmental releases.
• Work shall stop whenever formwork, equipment, utilities, access, weather, or other conditions create an uncontrolled hazard.

Training

Employees performing concrete work shall receive training appropriate to their assigned duties. Training shall address wet-concrete and cement hazards, silica exposure and controls, reinforcing-steel hazards, formwork and shoring, concrete placement, pump and hose hazards, ready-mix truck interaction, power tools, electrical hazards, fall protection, post-tensioning awareness, manual material handling, PPE, cleanup, and emergency procedures. Operators of concrete pumps, powered finishing equipment, saws, lifting equipment, and other specialized equipment shall receive additional training and authorization as required.

References

• OSHA 29 CFR 1926 Subpart Q – Concrete and Masonry Construction.
• OSHA 29 CFR 1926.701 – General Requirements.
• OSHA 29 CFR 1926.702 – Requirements for Equipment and Tools.
• OSHA 29 CFR 1926.703 – Requirements for Cast-in-Place Concrete.
• OSHA 29 CFR 1926.704 – Requirements for Precast Concrete, where applicable.
• OSHA 29 CFR 1926.1153 – Respirable Crystalline Silica.
• Applicable manufacturer instructions, engineering requirements, site procedures, and client requirements.