| Step | Potential Hazard | Control |
|---|---|---|
| Assess work area | Traffic hazards, uneven ground, poor lighting | Set up MUTCD compliant traffic control; conduct site walk; assign lookout |
| Inspect plugs, hoses, gauges, and PPE | Plug failure, hose rupture, defective gauges | Check plugs for cracks or wear; verify correct size; confirm ropes and gauges are in good condition |
| Don required PPE | Exposure to sewage, aerosols, chemical hazards | Wear gloves, face shield, waterproof boots or waders, high visibility vest, and respirator if needed |
| Test atmosphere near manhole | Hydrogen sulfide, methane, low oxygen | Use gas monitor at top, mid, and bottom of manhole; do not enter if unsafe; ventilate if necessary |
| Open manhole or access point | Fall hazards, sudden odor release | Use proper lifting tools; set cover aside securely; install temporary barriers |
| Identify flow conditions | Unexpected surges, high flow, debris | Observe water level; communicate with plant or lift station operators; isolate flow if possible |
| Lower plug into pipe using rope | Dropped plug, sudden flow, splash hazards | Keep hands clear of manhole edge; lower plug slowly using safety rope; avoid standing directly above opening |
| Position plug in pipe | Plug ejection, poor seating, entrapment | Do not enter pipe; use poles or rope for positioning; ensure plug is fully inside pipe and centered |
| Inflate plug to manufacturer pressure | Plug burst, hose whip | Stand to the side; do not exceed rated inflation pressure; monitor gauge constantly during inflation |
| Secure plug with safety rope | Plug blowout, uncontrolled movement | Tie rope securely outside the manhole; ensure slack allows slight movement without entering pipe |
| Verify seal and monitor pressure | Loss of seal, sudden release | Check pressure frequently; listen for leaks; monitor for pressure drop over time |
| Restrict access near manhole | Plug ejection, hazard to bystanders | Keep unauthorized personnel away; maintain exclusion zone |
| Deflate plug after use | Sudden splash, rapid movement | Stand to the side; release air slowly; maintain grip on safety rope |
| Remove plug from pipe | Dropped object, splash hazards | Pull plug up slowly using rope; avoid jerking motion; keep plug away from face and body |
| Clean and disinfect plug and tools | Contamination, chemical exposure | Rinse with approved disinfectant; avoid rinsing into storm drains |
| Replace manhole cover | Pinch points, back strain | Lift with manhole hook; place cover carefully; ensure it is properly seated |
| Final site cleanup | Slips, contamination, trip hazards | Remove debris; rinse area if allowed; ensure no tools remain |
| Remove traffic control | Exposure to moving 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
Steel toe boots
Waterproof boots or waders
Chemical resistant gloves (nitrile or neoprene)
Long pants and long sleeves
Respirator when working near sewage aerosols or strong odors
Disposable coveralls when contamination risk is heavy
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 hazards, uneven ground, poor lighting | Set up MUTCD compliant traffic control; conduct site walk; assign lookout |
| Inspect plugs, hoses, gauges, and PPE | Plug failure, hose rupture, defective gauges | Check plugs for cracks or wear; verify correct size; confirm ropes and gauges are in good condition |
| Don required PPE | Exposure to sewage, aerosols, chemical hazards | Wear gloves, face shield, waterproof boots or waders, high visibility vest, and respirator if needed |
| Test atmosphere near manhole | Hydrogen sulfide, methane, low oxygen | Use gas monitor at top, mid, and bottom of manhole; do not enter if unsafe; ventilate if necessary |
| Open manhole or access point | Fall hazards, sudden odor release | Use proper lifting tools; set cover aside securely; install temporary barriers |
| Identify flow conditions | Unexpected surges, high flow, debris | Observe water level; communicate with plant or lift station operators; isolate flow if possible |
| Lower plug into pipe using rope | Dropped plug, sudden flow, splash hazards | Keep hands clear of manhole edge; lower plug slowly using safety rope; avoid standing directly above opening |
| Position plug in pipe | Plug ejection, poor seating, entrapment | Do not enter pipe; use poles or rope for positioning; ensure plug is fully inside pipe and centered |
| Inflate plug to manufacturer pressure | Plug burst, hose whip | Stand to the side; do not exceed rated inflation pressure; monitor gauge constantly during inflation |
| Secure plug with safety rope | Plug blowout, uncontrolled movement | Tie rope securely outside the manhole; ensure slack allows slight movement without entering pipe |
| Verify seal and monitor pressure | Loss of seal, sudden release | Check pressure frequently; listen for leaks; monitor for pressure drop over time |
| Restrict access near manhole | Plug ejection, hazard to bystanders | Keep unauthorized personnel away; maintain exclusion zone |
| Deflate plug after use | Sudden splash, rapid movement | Stand to the side; release air slowly; maintain grip on safety rope |
| Remove plug from pipe | Dropped object, splash hazards | Pull plug up slowly using rope; avoid jerking motion; keep plug away from face and body |
| Clean and disinfect plug and tools | Contamination, chemical exposure | Rinse with approved disinfectant; avoid rinsing into storm drains |
| Replace manhole cover | Pinch points, back strain | Lift with manhole hook; place cover carefully; ensure it is properly seated |
| Final site cleanup | Slips, contamination, trip hazards | Remove debris; rinse area if allowed; ensure no tools remain |
| Remove traffic control | Exposure to moving 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
Steel toe boots
Waterproof boots or waders
Chemical resistant gloves (nitrile or neoprene)
Long pants and long sleeves
Respirator when working near sewage aerosols or strong odors
Disposable coveralls when contamination risk is heavy