| Step | Potential Hazard | Control |
|---|---|---|
| Assess work area | Traffic exposure, uneven pavement, poor visibility | Conduct site walk; establish MUTCD compliant traffic control; assign lookout |
| Inspect tools and replacement materials | Damaged lifting hooks, defective saw, cracked frame | Inspect saw blades, lifting chains, and replacement components; remove defective items |
| Don required PPE | Flying debris, dust, cutting hazards | Wear safety glasses or face shield, gloves, hard hat, high visibility vest, and respirator if sawing |
| Remove existing cover | Back strain, hand injuries, dropped cover | Use manhole hook; lift from stable footing; set cover down carefully; avoid fingers under edge |
| Cut or remove pavement around frame (if needed) | Flying concrete chips, saw kickback, dust inhalation | Use saw with proper guards; wet cut to reduce dust; keep bystanders clear; maintain firm footing |
| Excavate around frame (if required) | Struck by equipment, unstable excavation | Keep workers out of swing radius; position equipment on firm ground; maintain spoil piles away from excavation |
| Break out old frame and bedding | Flying debris, pinch points, tool rebound | Use sledge and chisel carefully; stand clear of rebound zone; remove loosened concrete by hand tools |
| Clean and prepare surface | Dust, sharp edges | Brush debris away; use scraper or grinder; wear eye and respiratory protection |
| Set new frame | Pinch points, dropped materials, misalignment | Use lifting straps or two person lift; place frame level; check alignment with existing structure |
| Apply mortar or grout bedding | Skin irritation, cement burns | Wear gloves; mix mortar carefully; avoid direct contact with wet cement |
| Adjust frame height for grade | Improper seating, trip hazard | Ensure frame height matches road grade; use leveling tools; follow municipal standards |
| Install new cover | Crushed fingers, dropped cover | Lower cover carefully; check fit; keep fingers away from seat |
| Patch surrounding pavement | Trip hazards, hot asphalt exposure | Compact asphalt carefully; keep workers clear of rollers; allow curing before traffic use |
| Final inspection | Sunken frame, rocking cover, debris | Check levelness, fit, and seating; ensure surface is smooth; remove all debris |
| Clean tools and site | Slips, dust, sharp debris | Remove leftover materials; rinse tools; sweep area clean |
| Remove traffic control | Exposure to traffic | Remove cones and signs in reverse order; maintain lookout; keep PPE on until clear |
Hard hat
Safety glasses or face shield
High visibility vest or jacket (Class 3 if roadside)
Steel toe boots
Cut resistant gloves
Long pants and long sleeves
Hearing protection when cutting or grinding
Respirator when exposed to dust or concrete particles
Always have a complete, well-stocked first aid kit available.
JSA Category: Water and Sewer Department Operations
* The steps, hazards, and controls displayed above may be incomplete or not suit your department's needs. All job safety analyses should be a completed with frontline worker input to ensure that each potential hazard is identified and mitigated.
Please read about The Essentials Elements of a Solid Job Safety Anaylsis here.
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| Step | Potential Hazard | Control |
|---|---|---|
| Assess work area | Traffic exposure, uneven pavement, poor visibility | Conduct site walk; establish MUTCD compliant traffic control; assign lookout |
| Inspect tools and replacement materials | Damaged lifting hooks, defective saw, cracked frame | Inspect saw blades, lifting chains, and replacement components; remove defective items |
| Don required PPE | Flying debris, dust, cutting hazards | Wear safety glasses or face shield, gloves, hard hat, high visibility vest, and respirator if sawing |
| Remove existing cover | Back strain, hand injuries, dropped cover | Use manhole hook; lift from stable footing; set cover down carefully; avoid fingers under edge |
| Cut or remove pavement around frame (if needed) | Flying concrete chips, saw kickback, dust inhalation | Use saw with proper guards; wet cut to reduce dust; keep bystanders clear; maintain firm footing |
| Excavate around frame (if required) | Struck by equipment, unstable excavation | Keep workers out of swing radius; position equipment on firm ground; maintain spoil piles away from excavation |
| Break out old frame and bedding | Flying debris, pinch points, tool rebound | Use sledge and chisel carefully; stand clear of rebound zone; remove loosened concrete by hand tools |
| Clean and prepare surface | Dust, sharp edges | Brush debris away; use scraper or grinder; wear eye and respiratory protection |
| Set new frame | Pinch points, dropped materials, misalignment | Use lifting straps or two person lift; place frame level; check alignment with existing structure |
| Apply mortar or grout bedding | Skin irritation, cement burns | Wear gloves; mix mortar carefully; avoid direct contact with wet cement |
| Adjust frame height for grade | Improper seating, trip hazard | Ensure frame height matches road grade; use leveling tools; follow municipal standards |
| Install new cover | Crushed fingers, dropped cover | Lower cover carefully; check fit; keep fingers away from seat |
| Patch surrounding pavement | Trip hazards, hot asphalt exposure | Compact asphalt carefully; keep workers clear of rollers; allow curing before traffic use |
| Final inspection | Sunken frame, rocking cover, debris | Check levelness, fit, and seating; ensure surface is smooth; remove all debris |
| Clean tools and site | Slips, dust, sharp debris | Remove leftover materials; rinse tools; sweep area clean |
| Remove traffic control | Exposure to traffic | Remove cones and signs in reverse order; maintain lookout; keep PPE on until clear |
Hard hat
Safety glasses or face shield
High visibility vest or jacket (Class 3 if roadside)
Steel toe boots
Cut resistant gloves
Long pants and long sleeves
Hearing protection when cutting or grinding
Respirator when exposed to dust or concrete particles