12 Aug Directional Boring – JSA

Directional Boring Job Safety Analysis (JSA)

Job / Task

Horizontal directional drilling (HDD) and boring operations, including site preparation, utility locating and potholing, drill setup, pilot boring, tracking, reaming, product installation, drilling-fluid handling, equipment breakdown, and site restoration.

Purpose

This Job Safety Analysis (JSA), also known as a Job Hazard Analysis (JHA), identifies hazards associated with directional boring and establishes controls to prevent utility strikes, electrocution, fire or explosion, struck-by and caught-between injuries, rotating-equipment contact, drilling-fluid exposure, equipment rollover, and other injuries.

Personnel Qualifications

Directional boring shall be performed by trained and authorized personnel familiar with the drilling equipment, locating system, utility-clearance procedures, drilling-fluid system, manufacturer instructions, and emergency procedures. Operators, locators, and other crew members shall understand their assigned roles and communication methods.

Employees shall:

• Understand the planned bore path, depth, entry and exit locations, and identified utility crossings.
• Complete required utility-location and exposure procedures before drilling.
• Use only drilling, locating, vacuum excavation, mixing, and support equipment for which they are trained.
• Maintain communication between the drill operator, locator, excavation personnel, and other affected workers.
• Remain clear of rotating drill rods, tooling, pinch points, moving equipment, and pressurized systems.
• Follow electrical-contact, gas-line strike, drilling-fluid release, and other emergency procedures.
• Stop work when utility location, tracking information, bore-path control, equipment condition, or communication becomes uncertain.

Required PPE

PPE shall be selected based on the work activity and site hazards and may include:

• Hard hat.
• Safety glasses with side protection.
• Face shield where splash or flying-particle hazards require additional protection.
• Safety footwear.
• Work gloves appropriate for handling drill rods, tooling, and drilling materials.
• High-visibility apparel.
• Hearing protection where required.
• Chemical-resistant gloves and protective clothing when handling drilling fluids or additives as required by product information.
• Respiratory protection when required by an exposure assessment and respiratory-protection program.
• Fall protection where required.
• Additional task-specific PPE identified by the hazard assessment.

JSA – Job Steps, Hazards, and Controls

Step 1 – Plan the Bore

Potential Hazards

• Utility strike.
• Incorrect bore path.
• Surface or structural damage.

Required Controls

• Review drawings, specifications, bore length, diameter, depth, entry angle, exit point, and product to be installed.
• Identify utility crossings, structures, roadways, waterways, environmentally sensitive areas, and other obstacles.
• Determine required equipment, tooling, drilling fluid, locating method, and work-zone controls.
• Establish the planned bore profile and acceptable deviation limits.
• Conduct a pre-task briefing with the drilling crew.

Step 2 – Complete Utility Notifications and Locating

Potential Hazards

• Electrocution.
• Gas release.
• Flooding.
• Service interruption.

Required Controls

• Complete required one-call and private utility-locating procedures before ground disturbance.
• Review utility markings, records, drawings, and visible surface indicators.
• Identify utilities not covered by the public locating service.
• Maintain required utility tickets and markings throughout the work.
• Do not begin boring until required utility responses and site verifications are complete.

Step 3 – Pothole / Daylight Critical Utilities

Potential Hazards

• Utility damage.
• Electrical contact.
• Gas release.
• Flying debris.

Required Controls

• Physically expose critical utility crossings and other required locations using approved methods.
• Use hand digging, vacuum excavation, or another approved non-destructive method.
• Verify horizontal and vertical utility location before drilling nearby.
• Protect exposed utilities from damage and unsupported movement.
• Stop work if actual utility locations differ from markings or records.

Step 4 – Walk and Mark the Bore Path

Potential Hazards

• Unrecognized hazards.
• Traffic exposure.
• Incorrect alignment.

Required Controls

• Walk the complete bore route before setup.
• Mark the entry, exit, utility crossings, potholes, and other critical points.
• Identify overhead power lines, traffic, pedestrians, slopes, excavations, structures, and access restrictions.
• Confirm the locator can safely access the bore path.
• Adjust the plan before drilling if conditions conflict with the proposed route.

Step 5 – Establish the Work Zone

Potential Hazards

• Vehicle strike.
• Unauthorized entry.
• Equipment interaction.

Required Controls

• Set up barricades, cones, signs, fencing, or other traffic and pedestrian controls as required.
• Separate workers from moving traffic and equipment where practical.
• Establish controlled areas around the drill, mixing system, pits, and product pipe.
• Maintain clear emergency access.
• Provide adequate lighting for low-light operations.

Step 6 – Inspect the Directional Drill

Potential Hazards

• Equipment failure.
• Unexpected movement.
• Hydraulic leak.

Required Controls

• Perform the required pre-use inspection.
• Inspect controls, emergency shutdowns, guards, tracks or tires, anchors, rod loader, hydraulic systems, and safety devices.
• Inspect drill rods and tooling for excessive wear, cracking, deformation, or damaged threads.
• Remove defective equipment or components from service.
• Verify required manuals and safety information are available.

Step 7 – Position and Set Up the Drill

Potential Hazards

• Rollover.
• Crushing.
• Unexpected movement.

Required Controls

• Position the drill on firm, stable ground.
• Maintain safe distance from excavation edges, unstable slopes, and other hazards.
• Deploy anchors or stabilizers according to manufacturer instructions.
• Establish an exclusion zone around moving and anchoring components.
• Verify the drill is aligned with the planned bore path before drilling.

Step 8 – Check Overhead Electrical Clearances

Potential Hazards

• Electrocution.
• Arc flash.
• Equipment contact with power lines.

Required Controls

• Identify overhead power lines before positioning equipment, drill rods, vacuum equipment, cranes, or product pipe.
• Maintain applicable minimum approach distances.
• Use a dedicated spotter where equipment movement could approach electrical lines.
• Do not handle long conductive materials where they could contact energized lines.
• Relocate equipment or have lines appropriately controlled when required clearance cannot be maintained.

Step 9 – Set Up the Drilling-Fluid System

Potential Hazards

• Chemical exposure.
• Slips.
• Entanglement.
• Pressurized release.

Required Controls

• Review safety information for bentonite, polymers, and other additives.
• Inspect mixing equipment, hoses, tanks, guards, and connections.
• Keep hands and clothing clear of mixers and moving components.
• Use required eye, hand, and respiratory protection when handling dry additives.
• Clean spills promptly to control slip hazards.

Step 10 – Load / Handle Drill Rods and Tooling

Potential Hazards

• Pinch points.
• Crushing.
• Strains.
• Sharp edges.

Required Controls

• Use mechanical rod-loading systems where provided.
• Keep hands clear of rod loaders, clamps, vises, and threaded connections.
• Do not manually handle rods while automated loading components are moving.
• Use proper lifting techniques for tooling and heavy components.
• Wear gloves suitable for sharp or rough surfaces.

Step 11 – Start the Pilot Bore

Potential Hazards

• Rotating-equipment contact.
• Unexpected drill movement.
• Utility strike.

Required Controls

• Clear unnecessary personnel from the drill operating area.
• Confirm communication between the operator and locator before rotation and thrust begin.
• Keep guards and protective devices in place.
• Do not reach across or approach rotating drill rods.
• Advance at a controlled rate consistent with soil conditions and the bore plan.

Step 12 – Track the Drill Head

Potential Hazards

• Incorrect depth or direction.
• Traffic exposure.
• Locator struck-by.

Required Controls

• Use the locating system according to manufacturer instructions.
• Record or monitor depth, pitch, direction, and position at appropriate intervals.
• Maintain communication with the drill operator.
• Keep the locator out of traffic lanes and equipment travel paths unless appropriate controls are in place.
• Stop drilling if reliable tracking information is lost.

Step 13 – Cross Existing Utilities

Potential Hazards

• Utility strike.
• Electrocution.
• Fire or explosion.

Required Controls

• Verify the exposed utility and bore-head position before crossing.
• Maintain required separation from the utility.
• Advance slowly through the crossing area.
• Use visual confirmation from potholes where required and safe.
• Stop immediately if the bore path, utility location, or separation becomes uncertain.

Step 14 – Maintain Operator / Locator Communication

Potential Hazards

• Miscommunication.
• Unexpected drill movement.
• Utility contact.

Required Controls

• Establish standard radio or hand-signal communication before drilling.
• Use clear commands for advance, stop, rotate, steer, and pullback operations.
• The operator shall stop drilling when communication is lost.
• Avoid conflicting instructions from multiple workers.
• Resume only after communication is restored and conditions are confirmed safe.

Step 15 – Monitor Ground Conditions

Potential Hazards

• Loss of bore control.
• Surface heave.
• Collapse or settlement.

Required Controls

• Monitor drilling resistance, fluid returns, ground movement, and surface conditions.
• Adjust drilling parameters to suit changing soil conditions.
• Stop work if unexpected voids, severe loss of returns, surface heave, settlement, or other abnormal conditions occur.
• Reevaluate the bore plan when significant geological changes are encountered.
• Keep personnel clear of unstable pits and excavations.

Step 16 – Respond to Loss of Drilling Fluid / Inadvertent Return

Potential Hazards

• Environmental release.
• Slip hazard.
• Property damage.

Required Controls

• Monitor the bore path and nearby surface areas for drilling-fluid returns.
• Stop or reduce drilling as necessary when an unintended return occurs.
• Contain and recover released drilling fluid using the site response plan.
• Protect storm drains, waterways, and sensitive areas.
• Notify required site, client, environmental, or regulatory personnel as applicable.

Step 17 – Exit the Pilot Bore

Potential Hazards

• Flying debris.
• Unexpected drill-head emergence.
• Struck-by.

Required Controls

• Barricade or control the exit area before the drill head emerges.
• Keep personnel clear of the anticipated emergence point.
• Advance slowly as the drill head approaches the surface or exit pit.
• Maintain communication between the operator and exit-side personnel.
• Do not stand directly in front of the expected drill-head path.

Step 18 – Change Tooling / Install Reamer

Potential Hazards

• Unexpected rotation.
• Crushing.
• Sharp tooling.

Required Controls

• Stop rotation and thrust and follow manufacturer procedures before approaching tooling.
• Isolate or disable equipment controls as required to prevent unexpected movement.
• Use mechanical assistance for heavy reamers and tooling.
• Keep hands clear of threaded joints and pinch points.
• Verify tooling is properly connected before pullback.

Step 19 – Perform Reaming Operations

Potential Hazards

• Rotating tooling.
• Ground movement.
• Utility contact.

Required Controls

• Use the reamer size and sequence specified for the bore and product.
• Maintain controlled rotation, pullback speed, and drilling-fluid flow.
• Continue monitoring utility clearances and surface conditions.
• Keep personnel clear of rotating rods and tooling.
• Stop if excessive torque, pullback force, vibration, or unexpected resistance occurs.

Step 20 – Stage Product Pipe / Conduit

Potential Hazards

• Rolling pipe.
• Traffic conflict.
• Manual-handling injury.

Required Controls

• Stage product on stable ground along a controlled route.
• Chock or restrain round pipe against rolling.
• Keep product clear of traffic and pedestrian routes where practical.
• Use mechanical assistance for heavy pipe.
• Provide adequate space for joining and pullback.

Step 21 – Join Product Pipe

Potential Hazards

• Pinch points.
• Burns.
• Chemical exposure.
• Equipment hazards.

Required Controls

• Follow the appropriate joining procedure for the pipe material.
• Use trained personnel for fusion, welding, solvent cementing, or mechanical joining.
• Maintain safe clearance from fusion clamps, heaters, welding equipment, and other moving or hot components.
• Allow required cooling or cure times.
• Inspect completed joints before pullback.

Step 22 – Connect the Product to the Pulling Assembly

Potential Hazards

• Pinch points.
• Rigging failure.
• Unexpected movement.

Required Controls

• Use a pulling head, swivel, and connectors rated for the anticipated load.
• Inspect the assembly before use.
• Keep personnel clear while connections are tensioned.
• Verify the swivel rotates freely where required.
• Do not use damaged or improvised pulling components.

Step 23 – Pull Back the Product

Potential Hazards

• Stored energy.
• Pipe movement.
• Struck-by.
• Equipment overload.

Required Controls

• Establish exclusion zones around the drill, product pipe, and pulling assembly.
• Keep personnel away from tensioned pipe and tooling.
• Monitor pullback force, rotation, fluid flow, and product movement.
• Stop if the product binds, pulling force becomes excessive, or abnormal movement occurs.
• Do not stand inside bends or other potential snapback areas.

Step 24 – Work Around Rotating Drill Rods

Potential Hazards

• Entanglement.
• Crushing.
• Amputation.

Required Controls

• Keep guards and barriers in place.
• Do not wear loose clothing or jewelry around rotating equipment.
• Never straddle, step over, or manually handle a rotating drill string.
• Stop rotation before employees enter the rod or tooling area.
• Use tools rather than hands where practical for positioning components.

Step 25 – Clear a Jam / Stuck Drill String

Potential Hazards

• Stored energy.
• Unexpected movement.
• Equipment failure.

Required Controls

• Stop operations and assess the cause before applying additional force.
• Follow manufacturer procedures for stuck tooling or drill rods.
• Keep personnel out of the line of pull and potential release path.
• Do not exceed equipment or tooling ratings.
• Isolate equipment before manual adjustment or disassembly.

Step 26 – Respond to Electrical Utility Contact

Potential Hazards

• Electrocution.
• Touch and step potential.
• Fire.

Required Controls

• Stop work immediately and warn others to stay away.
• The operator should remain on the equipment when safe to do so and avoid simultaneous contact with the equipment and ground.
• Keep ground personnel away from the drill, rods, tooling, and surrounding area until the electrical source is confirmed de-energized.
• Contact emergency services and the utility owner as required.
• Have equipment inspected before returning it to service.

Step 27 – Respond to Gas Utility Contact

Potential Hazards

• Explosion.
• Fire.
• Asphyxiation.

Required Controls

• Stop drilling immediately.
• Shut down equipment and ignition sources only when this can be done safely.
• Evacuate personnel to a safe location and prevent entry into the affected area.
• Contact emergency services and the gas utility immediately.
• Do not attempt repairs unless specifically trained, qualified, and authorized.

Step 28 – Respond to Other Utility Damage

Potential Hazards

• Flooding.
• Service interruption.
• Hazardous release.

Required Controls

• Stop work and keep personnel clear of the damaged installation.
• Notify the utility owner, supervisor, and site representative.
• Control secondary hazards only when safe to do so.
• Reevaluate excavation or ground stability if water is released.
• Resume work only after the utility hazard has been controlled.

Step 29 – Break Down Equipment

Potential Hazards

• Unexpected startup.
• Pinch points.
• Residual pressure.

Required Controls

• Stop and secure equipment according to manufacturer procedures.
• Relieve hydraulic, pneumatic, and drilling-fluid pressure before disconnecting components.
• Secure drill rods, tooling, hoses, and accessories for transport.
• Use mechanical assistance for heavy components.
• Keep hands clear of pinch points during folding or stowing operations.

Step 30 – Restore the Site

Potential Hazards

• Trips.
• Open pits.
• Residual drilling fluid.
• Public exposure.

Required Controls

• Remove excess drilling fluid, spoils, debris, and unused materials.
• Backfill and compact potholes, entry pits, and exit pits as required.
• Restore pavement, landscaping, barriers, and traffic controls according to project requirements.
• Remove barricades only after hazards are eliminated.
• Document utility damage, unusual bore conditions, or deviations as required.

General Safe Work Requirements

• Required utility notifications, locating, and potholing/daylighting shall be completed before directional boring begins.
• Critical utility crossings shall be positively identified and exposed where required before the bore passes nearby.
• The drill operator and locator shall maintain reliable communication during drilling and pullback operations.
• Drilling shall stop immediately when reliable tracking information or communication is lost.
• Employees shall remain clear of rotating drill rods, tooling, rod loaders, vises, pinch points, and tensioned product pipe.
• Guards and manufacturer-provided safety devices shall remain installed and functional.
• Directional drills shall be positioned and anchored on stable ground in accordance with manufacturer requirements.
• Applicable clearance shall be maintained from overhead electrical lines.
• Drilling-fluid additives shall be handled according to product safety information, and spills or inadvertent returns shall be controlled promptly.
• Entry pits, exit pits, potholes, and other excavations shall comply with applicable excavation requirements.
• Product pipe and drill rods shall be stored and handled to prevent rolling, shifting, or uncontrolled movement.
• Pulling heads, swivels, connectors, drill rods, reamers, and other components shall be rated and inspected for the intended load.
• Employees shall remain outside lines of pull, snapback zones, and other areas exposed to stored energy.
• Electrical or gas utility contact requires immediate stop work, area control, and implementation of emergency procedures.
• Defective drilling, locating, mixing, vacuum, or support equipment shall be removed from service.
• Work shall stop whenever utility clearance, bore-path control, ground conditions, equipment condition, environmental controls, or other safeguards are inadequate.

Training

Employees performing directional boring shall receive training appropriate to their duties. Training shall address utility locating and potholing, drill operation, locating equipment, bore-path planning, operator-locator communication, rotating-equipment and pinch-point hazards, drilling-fluid handling, inadvertent returns, product pullback, stored energy, traffic and pedestrian control, excavation hazards, overhead electrical hazards, utility-strike response, PPE, and emergency procedures. Operators, locators, vacuum-excavation personnel, and employees performing specialized joining or lifting activities shall receive additional training and authorization as required.

References

• OSHA 29 CFR 1926.651 – Specific Excavation Requirements.
• OSHA 29 CFR 1926 Subpart P – Excavations.
• OSHA 29 CFR 1926.416 – General Requirements for Electrical Safety.
• OSHA 29 CFR 1926 Subpart O – Motor Vehicles, Mechanized Equipment, and Marine Operations, where applicable.
• Applicable state one-call / utility-location requirements.
• Applicable manufacturer instructions, project specifications, site procedures, and client requirements.