First, describe the work and worksite
A qualified specialist crew will grout an identified bonded tendon duct in a building floor or beam after accepted stressing and anchorage work. The actual system method governs material, ports, vents, quality and completion evidence. This operation includes no stressing or invasive tendon investigation. This fictional learning example describes planned controls; it records no actual inspection or work authorization.
- The identified tendon has actual stressing and anchorage acceptance. Responsible authorities establish port and vent readiness and fill-completion evidence through the current bonded building-system method.
- Specified material, qualified personnel and accepted equipment are available. Quality limits, interruption response and protection come from the actual method; no universal mix, pressure, vent sequence or cure value is supplied.
- The grouting link 238110-20 is partial: initial grouting of a released bonded building tendon duct only. Unbonded systems, active stressing, jack operation, bridges or Heavy/Civil 237 work, drilling into tendons, void investigation and remedial injection require separate analyses.
Questions before work
- Which records identify this bonded tendon and release completed stressing and anchorage work for grouting?
- Who controls the exact port and vent method and verifies the specified material and fill-completion evidence?
- What is the accepted response to an interrupted fill, and who holds later structural work until disposition?
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. Establish the tendon-specific grouting release
Hazard: Confusing a duct, using incomplete stressing records or interfering with an anchorage can conceal an unready structural system and expose workers.
Control: Specialist lead identifies the tendon and obtains current drawings, accepted stressing and anchorage records and the actual grouting method. Resolve the port map, vent access and responsible technical hold points with the system authority. Keep active stressing and any investigation or correction of a disputed tendon outside this operation.
Verification: Lead verifies tendon identity and actual system release evidence.
Why this belongs in the analysis: A generic grout plan cannot release an identified duct.
2. Prepare protected ports, equipment and containment
Hazard: Unprotected access, misconnected hoses or an exposed discharge point can cause falls, hose movement or cementitious splash during filling.
Control: Crew prepares the accepted mixing and pumping location, protected access to designated ports and vents, controlled hose routing and collection at intended outlets. Complete the actual equipment and connection checks and set exclusion and communication arrangements. Keep hands and bodies away from anticipated discharge paths; do not drill or create replacement ports without responsible design direction.
Verification: Lead checks mapped connections, access and outlet collection before batching.
Why this belongs in the analysis: Protected mapped outlets must be ready before material flows.
3. Prepare and verify the specified grout batch
Hazard: Wrong material, uncontrolled added water or omitted quality checks can produce an unsuitable fill while dry powder and wet grout expose the mixing crew.
Control: Qualified crew confirms the specified product, lot and condition and batches through the accepted procedure using the required equipment. Apply the task’s dust, skin and eye controls and perform assigned grout-quality checks. Keep unaccepted material held; document only permitted adjustments and obtain the responsible disposition for a failed batch.
Verification: Assigned quality personnel record required batch results before use.
Why this belongs in the analysis: Pumpability alone does not establish accepted grout quality.
4. Fill through the accepted duct and vent method
Hazard: An improvised pressure or vent sequence can expose workers, leave an incomplete duct fill or damage the designated system.
Control: Qualified operator pumps through the identified inlet and follows the actual system’s controlled filling and vent procedure with assigned observers. Monitor only the indicators and limits specified for this tendon, maintain communication and collect the designated outlets. Stop for unexpected response, leakage or lost communication and keep the affected duct held for the accepted interruption decision.
Verification: Observers report the actual required flow and vent findings.
Why this belongs in the analysis: The enclosed duct requires actual system fill evidence.
5. Verify completion and protect the accepted fill
Hazard: Premature closure, undocumented interruptions or disturbance of connections can conceal incomplete corrosion protection or an unready structural condition.
Control: Specialist lead obtains the required completion and material evidence under the accepted method, including any prescribed closure and protection actions. Record anomalies and obtain responsible technical disposition rather than assuming a successful fill. Maintain the required protection and load restrictions; further checks or remedial work are separately planned if the evidence is incomplete.
Verification: Responsible personnel review completion evidence before releasing the hold.
Why this belongs in the analysis: Cycle completion and accepted tendon fill are separate decisions.
6. Shut down and transfer the tendon record
Hazard: Residual line energy, loose waste or an unclear structural handover can injure cleanup personnel and transfer a hidden fill concern to later work.
Control: Operator follows the equipment’s actual safe shutdown and routine cleaning method with pressure and energy conditions verified before permitted access. Capture grout and washwater and secure ports as required. Transfer the tendon identity, batch and fill records, interruptions, accepted dispositions and continuing restrictions to the receiving structural lead; keep unresolved work identified and held.
Verification: Lead confirms shutdown and outstanding actions with the receiving authority.
Why this belongs in the analysis: The handover preserves unresolved fill and structural restrictions.
What does a useful control look like?
| Needs improvement | More useful for this scenario |
|---|---|
| Use the baseplate grout sequence; it is the same bag. | Identify the bonded duct, required grout acceptance, specific inlet and vent method and tendon fill-completion evidence before use. |
| Grout reached one outlet, so the tendon is accepted. | Assigned personnel record every required completion finding and obtain the responsible disposition for interruptions and unresolved conditions. |
Decisions that change the analysis
Can a crew drill a new outlet when the expected vent does not respond?
No. Stop through the accepted system procedure and maintain the affected tendon’s hold. Obtain direction from the responsible structural and system authorities; drilling can intersect reinforcement, the duct or stressed steel and is outside this initial grouting operation. An improvised outlet or higher pump pressure cannot replace the actual interruption and investigation method.
What must the crew record for actual use?
Record tendon, duct and procedure identity, stressing and anchorage release basis, assigned qualified roles, actual connection and batch results and required fill findings. Document interruptions, dispositions, closure, protection and structural handover restrictions; identify the accepting authority and unresolved work without prefilled acceptance.
Agree when the crew will pause
- Tendon identity, completed stressing and anchorage acceptance or the current bonded-system method cannot be confirmed.
- Batch results, flow, vent response, pressure behavior or leakage differ from the accepted procedure, or communication is lost.
- A port, access condition, interruption or suspected void requires unplanned modification, investigation or remedial work.
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 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
- System-specific instruction for qualified grouting personnel on identified ports and vents, accepted batch-quality checks, controlled pumping and the designated interruption procedure.
- Instruction on cementitious exposure, pressure-line hazards, safe port access, communication and protecting the completed tendon without drilling or disturbing anchorage work.
Confirm applicable qualifications, task instruction and actual training evidence for the people assigned. Related toolbox talks support toolbox talks; they do not establish competence.
Common questions
Can this example be used as a JSA?
Adapt the Task | Hazard | Control analysis to the employer’s JSA and actual work. Confirm assigned checks and record real findings before use.
What changes if the project requires an AHA?
Use the project’s governing AHA format, risk method and acceptance process. The published formwork AHA illustrates additional structure; this example supplies no AHA risk rating or acceptance.
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
- SikaGrout Cable PT: bonded post-tensioning duct grout requirements
- The Concrete Society Grouting of post-tensioned tendons
- OSHA 1926.701 General concrete construction requirements
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. This example supplies no inspection findings or work authorization. Use actual equipment instructions and site requirements alongside these references. Reference review: October 9, 2026.