First, describe the work and worksite
A repair crew will install engineer-specified reinforcing starter bars into already drilled and released horizontal holes in a ground-level concrete foundation face. The selected adhesive system and installation records govern hole preparation, placement and cure restrictions. This fictional learning example describes planned controls; it records no actual inspection or work authorization.
- The actual bar schedule, embedment, concrete condition and adhesive approval must be established by the project design.
- Hole drilling and structural penetration clearance are complete and separately documented; receiving a hole does not prove it meets adhesive installation criteria.
- This is partial coverage of drilling and dowel installation. New drilling, overhead bars, crack injection, pull testing and loading before authorized release are excluded.
Questions before work
- Which design and adhesive instructions apply to this bar, hole method and concrete condition?
- How will installers control dust during the permitted cleaning process and chemical exposure during dispensing?
- Who records substrate temperature, installation time, cure restrictions and the subsequent loading release?
Build the analysis one step at a time
What will the worker do? How could someone be harmed? What prevents or reduces that exposure? Who checks the control, and when?
1. Accept the connection design
Hazard: Wrong bars, embedment or an unsuitable base material can create a fastening that later fails under load.
Control: Installation lead compares the released bar and hole schedule with the actual concrete and approved adhesive system. Obtain the required inspection arrangements; hold undocumented holes or conditions outside the design and product approval.
Verification: Lead checks hole identification, schedule and supporting release before preparation.
Why this belongs in the analysis: A structural adhesive connection needs more than a convenient drilled hole.
2. Prepare the installation station
Hazard: Adhesive contact, splash or unexpected movement of long bars can injure nearby workers.
Control: Arrange labeled products, current SDS, washing supplies and specified hand and eye protection. Support the bars, separate the work from passersby and establish a controlled dispensing/waste area with product-required ventilation.
Verification: Foreperson checks chemical controls and bar-handling space before packs are opened.
Why this belongs in the analysis: Exposure control and bar support must exist before dispensing begins.
3. Verify and clean receiving holes
Hazard: Dust or unsuitable hole condition can impair bonding; cleaning can expose the crew to airborne silica.
Control: Installer verifies the specified hole dimensions and condition, then uses the actual system’s approved cleaning tools and method. Assess silica exposure for that method; do not substitute a quick air blast or assume vacuuming alone satisfies the product instructions.
Verification: Installer records the accepted hole condition and cleaning method for the installation review.
Why this belongs in the analysis: Both bond reliability and worker exposure depend on how cleaning is performed.
4. Prepare and dispense adhesive
Hazard: Expired material, incorrect mixing or chemical leakage can harm people and leave an unreliable connection.
Control: Check product identity, storage condition, expiration, dispenser and mixing nozzle against instructions. Follow the specified initial discard and filling method while controlling splash and waste; stop for damage or inconsistent material.
Verification: Installer verifies pack identity and dispensing readiness before filling each released hole.
Why this belongs in the analysis: A full-looking hole does not establish a correctly mixed adhesive system.
5. Insert bars and protect the cure
Hazard: A displaced bar or early load can disturb the adhesive; exposed ends can create impalement exposure.
Control: Mark the specified embedment and install bars by the approved method within actual working limits. Maintain required bar support and movement restrictions throughout the product-specific cure; guard fall-onto protruding steel exposures.
Verification: Installer records bar position, substrate conditions and installation times; lead checks protection.
Why this belongs in the analysis: Cure limits come from the selected system and conditions, not a universal waiting time.
6. Record and hand over restrictions
Hazard: Another crew can use an unaccepted dowel as a handle or load an incompletely cured connection.
Control: Mark unreleased connections and transfer installation records, cure restrictions and unresolved findings to the responsible reviewer. Loading or further connection work proceeds only after its required acceptance and release; dispose of waste under product and site arrangements.
Verification: Lead confirms the receiving crew understands the marked restrictions and outstanding review.
Why this belongs in the analysis: Installation completion and permission to load are separate decisions.
What does a useful control look like?
| Needs improvement | More useful for this scenario |
|---|---|
| Blow out the hole and epoxy the bar. | Installer uses the selected system’s approved cleaning method with assessed silica controls, then records hole acceptance and installation conditions. |
| Wait until the epoxy looks hard. | Installer records actual substrate conditions and installation times; the responsible reviewer applies the system-specific cure and loading criteria before release. |
Decisions that change the analysis
Can any cleaned hole accept any rebar adhesive?
No. Hole formation, dimensions, base condition, bar and cleaning method must match the design and selected system. This example begins with released drilled holes but still requires installation-condition acceptance.
What must the crew record for actual use?
Record the design revision, hole and bar identification, product/lot and expiration, approved preparation method, actual substrate conditions and installation times, embedment findings, cure restrictions, inspection actions and loading release.
Agree when the crew will pause
- Hole size, concrete condition or drilling method differs from the released system.
- Adhesive condition, mixing, temperature or working/cure limit is outside the product criteria.
- A bar moves during cure or impalement guarding and installation records are lost.
After a pause, correct the condition, reassess the work, and obtain required authorization before restarting. Keep unresolved actions visible.
Download the worked example and free template
No account or paid membership required. The worked example contains planned controls. The blank template is for your own work; neither includes fabricated inspection results, signatures or approval.
Your editable working copy
Build and download your draft
Start blank or load the learning example. Replace its assumptions with your actual conditions and involve the people doing the work. Your entries stay in this browser tab; download a copy before leaving or refreshing.
1. Describe your work and site
2. Work through each task
Describe an observable step, how someone could be harmed, and the control that acts on that hazard. Identify who checks it and what evidence is needed.
3. Record changes, checks, and open actions
Walk the work area, review with the crew, and resolve missing controls. Follow the required approval process. This tool does not judge completeness, verify signatures or authorize work.
Open the downloaded file in a browser, then use Print → Save as PDF for a printable copy.
Training needs to confirm
- Instruction and any required qualification for the selected adhesive rebar system, cleaning accessories, dispensing and cure limits.
- Hazard-communication and exposure-control instruction for the adhesive, hole-cleaning dust and protruding bar protection.
Confirm applicable qualifications, task instruction and actual training evidence for the people assigned. Related toolbox talks support crew discussion; they do not establish competence.
Common questions
Can this example be used as a JSA?
Adapt its Task | Hazard | Control analysis to the employer’s format and actual conditions. The example is a teaching aid, not evidence that controls were checked.
What changes if the project requires an AHA?
Use the governing AHA format, risk method, supporting records and acceptance process. The published formwork AHA demonstrates that additional structure; changing a JHA title does not supply it.
Are these resources part of a paid course?
This walkthrough, browser draft builder and downloads are free public resources, separate from Academy course enrollment.
References and source note
- Hilti USA Adhesive anchors and product instructions
- Hilti USA Approved hole-cleaning methods
- OSHA 1910.1200 Hazard communication
Original instructional scenario with planned controls. Primary references support hazard planning. Use actual equipment and product instructions, project design and employer requirements to establish field criteria. Use actual equipment instructions and site requirements alongside these references. Reference review: October 9, 2026.