First, describe the work and worksite
A trained pump-line crew will assemble an uncharged rigid concrete delivery pipeline along a released ground-level route for a building pour. Identified compatible pipes, bends, seals and couplings are installed on designed supports through the actual selected-system method. The completed line stays unavailable for flow until a separate pumping-readiness handover. This fictional learning example describes planned controls and records no actual inspection or work authorization.
- The actual pump and complete delivery-system arrangement are identified. Required pressure compatibility, component wear acceptance, coupling instructions and support design are available; the weakest identified component governs suitability, without a universal rating or wear value.
- The entire assembly is uncharged, empty and separated from any source that could introduce pressure or concrete during the work. Prepared supports, permitted handling equipment, stable access and protection from site traffic are released before components move.
- Pump setup 238110-14 and pumping 238110-15 are partial connections: ground rigid-line construction before priming only. End-hose handling, active-line extension, high-rise risers, pump erection, pressure testing, blockage intervention, cleanout and field welding are excluded.
Questions before work
- Which actual pump duty and selected component instructions establish compatibility and remaining wear acceptance?
- What supports and route controls protect the assembled line, its handling crew and nearby access?
- Who maintains the no-flow condition and receives the actual assembly evidence before separate pumping readiness?
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 released uncharged system boundary
Hazard: An unidentified connection to pumping equipment can introduce concrete or pressure while people are assembling the line.
Control: Assembly lead identifies the complete route, pump interface and selected-system package with the pump operator. Establish and maintain the actual arrangement preventing flow or pressure throughout assembly, including any necessary equipment controls under the employer's procedure. Hold uncertainty or evidence of retained material/pressure. This example begins with a known empty uncharged system and gives no method for opening an active or blocked line.
Verification: Lead and operator confirm the actual no-flow boundary and assigned control ownership.
Why this belongs in the analysis: A safe assembly condition must be established positively before anyone handles a coupling.
2. Accept the route and designed supports
Hazard: Unsupported pipe, conflicting traffic or an unverified bearing surface can cause movement during assembly and later pumping.
Control: Check the released ground route, access, buried services and traffic separation. Identify overhead power lines and nearby electrical sources and establish the applicable clearance and control arrangements before any prescribed mechanical pipe transfer. Obtain acceptance of specified supports/restraint, including required pumping-load design and OSHA discharge-pipe support requirements. Keep exits available, prevent vehicle impact and hold changed support conditions for responsible review.
Verification: Lead verifies actual support evidence and the protected route before laying pipe.
Why this belongs in the analysis: The line's later filled and operating condition requires a designed support path at setup.
3. Match and examine the complete component set
Hazard: An incompatible end, damaged coupling or unaccepted worn pipe can fail despite an apparently closed joint.
Control: Assigned personnel identify pipes, bends, seals, couplings and retention devices against the selected system and intended pump duty. Review required condition and wear records and perform prescribed checks of mating surfaces, threads, hinges, ends and seals. Segregate uncertain or damaged parts for disposition. Do not assume similar diameter establishes compatibility or use a readable label as proof of adequate remaining wear condition.
Verification: Lead records component match, actual required wear/condition findings and rejected items.
Why this belongs in the analysis: Compatibility and condition must be established together for each part of the delivery path.
4. Position supported sections and complete couplings
Hazard: Rolling heavy sections, unsupported ends or hands between mating pipes can cause crushing and lead to forced misalignment.
Control: Use the planned handling equipment and coordinated commands to position manageable sections on accepted supports. Keep bodies outside rolling and closing gaps and retain section support while joining. Trained installers complete only the exact manufacturer's seal, engagement, fastening and retention method. Stop for incorrect fit or excessive required effort; do not hammer a mismatched joint closed or substitute an invented bolt-torque or clamp-adjustment recipe.
Verification: Installer checks supported fit and each prescribed coupling/retention condition before progressing.
Why this belongs in the analysis: Controlled support allows the joint to be assembled without people holding its load or forcing a defect.
5. Review the complete assembly before handover
Hazard: A missed retention device, support change or damaged interface can remain hidden until priming subjects the line to operating forces.
Control: Assigned checker follows the accepted assembly verification route across the entire line and documents required joint, support and interface findings. Resolve defects through the selected system and responsible planner while the uncharged boundary remains effective. Preserve access to required observations. This check does not include a crew-devised pressure test, concrete flow or trial opening of a connection.
Verification: Lead reviews actual complete-line findings and keeps unresolved sections unavailable for pumping.
Why this belongs in the analysis: The assembled system needs a complete verified condition, beyond checks of individual loose parts.
6. Transfer assembly evidence and preserve pumping holds
Hazard: An operator may start flow before hose, exclusion or priming readiness is separately established, exposing workers still beside connections.
Control: Record system identity, route, components, wear basis, supports, installation findings and held issues. Remove unused parts and keep line protection visible. Transfer the actual assembly state to the pump lead and confirm that later hose configuration, priming positions, operating checks and start authority remain under the separate pumping plan. Keep the no-flow condition until that handover and release are complete.
Verification: Receiving pump lead confirms line status, protection ownership and separate startup requirements.
Why this belongs in the analysis: Pipeline construction ends with a controlled interface to operation, not an assumed permission to pump.
What does a useful control look like?
| Needs improvement | More useful for this scenario |
|---|---|
| All the clamps are the same size, so the system matches. | Verify compatible ends, pressure duty, actual wear/condition evidence and the selected coupling's prescribed retention. |
| The line is connected; start the pump now. | Hand over the complete assembly evidence while retaining the separate hose, priming, exclusion and pumping-start holds. |
Decisions that change the analysis
May a line section be added while delivery continues elsewhere?
That changes the established empty uncharged assembly boundary and is outside this example. Keep the proposed intervention held for a separate equipment-specific plan addressing isolation, trapped energy, connected sections and actual verification. Stopping visible discharge or removing a safety pin is not evidence that a concrete delivery connection is safe to open.
What must the crew record for actual use?
Record pump and system identities, released route/support package, actual component and wear acceptance, no-flow arrangements, installation and retention findings and defects. Identify responsible dispositions, complete-line verification, receiving pump lead and remaining startup requirements. Supply real evidence without prefilled inspection results, a claimed pressure test or permission to introduce concrete.
Agree when the crew will pause
- The actual uncharged boundary, pump/system compatibility, required wear evidence or applicable coupling method is unresolved.
- Ground route, supports, component condition, fit or prescribed retention differs from the released assembly package.
- Flow, pressure testing, active-line modification or a blocked/charged connection is proposed through this assembly example.
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
- Selected delivery-pipeline assembly instruction on component identity, wear acceptance, support, coupling engagement and required retention checks.
- Instruction on heavy pipe and pinch paths, maintained uncharged-system boundaries, defect reporting and the separate priming/flow handover.
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 adapted to a JSA?
Use its Task | Hazard | Control analysis in the employer's actual JSA format. Confirm the scenario, assigned verification and real findings before relying on the adapted work plan.
What changes when the project requires an AHA?
Apply the governing AHA format, risk method, supporting records and acceptance process. The published formwork AHA illustrates additional structure; this JHA supplies no completed AHA 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
- ESSER coupling inspection sheet: compatibility, condition, engagement and retention
- Putzmeister delivery-line systems: matching components and measured wear
- OSHA 1926.702 Equipment and tools: concrete pumping discharge-pipe supports
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 13, 2026.