First, describe the work and worksite
A masonry crew will pump specified cementitious grout into released reinforced CMU cells using a small grout pump and hose from protected access. This fictional learning example records planned controls; it supplies no actual inspections or work authorization.
- Wall stability, cell preparation and placement sequence are released under the masonry plan.
- Pump, hose, restraint and blockage methods must match the actual equipment and grout.
- This excludes concrete slab pumping, mortar mixing and unsupported wall construction.
Questions before work
- Who releases wall stability and the grout lift sequence?
- Which hose connections and restraints does the pump require?
- How will a blockage be depressurized without exposing the crew?
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 wall for grouting
Hazard: Placement load or an unstable wall can cause collapse.
Control: Masonry supervisor confirms wall support, limited-access arrangements and the released grout sequence. Hold pumping for unresolved wall or access conditions.
Verification: Compare the wall and intended lift with the current masonry plan.
Why this belongs in the analysis: A standing wall is not automatically ready for grout pressure and loading.
2. Position the pump and route the hose
Hazard: Equipment movement or a crossing hose can strike or trip workers.
Control: Place the pump on suitable support, separate deliveries and route the hose with protected access. Provide safe receiving access without changing wall braces.
Verification: Lead walks the pump, hose and receiving route before setup.
Why this belongs in the analysis: Hose routing must serve both placement and escape.
3. Inspect pump, connections and guards
Hazard: A failed coupling, exposed mechanism or incompatible hose can cause injury.
Control: Operator checks equipment, pressure rating, guards, couplings and required restraints against the model instructions. Remove defective components from service.
Verification: Record the pre-use checks and resolve defects before charging.
Why this belongs in the analysis: A connected hose is not evidence of a suitable pressure system.
4. Pump the released cells
Hazard: Hose movement, cement splash or excessive placement can injure workers or destabilize the wall.
Control: Use the specified pump and wall placement sequence with coordinated start and stop signals. Maintain cement protection and wall boundaries; stop for hose movement, leaks or unexpected wall response.
Verification: Pump operator and placement lead maintain communication and monitor the hose and wall.
Why this belongs in the analysis: The receiver and operator must share the same stop decision.
5. Manage a blockage or cleanout
Hazard: Stored pressure can eject grout or whip a hose when opened.
Control: Stop and use the manufacturer’s pressure-release and blockage procedure. Verify the required safe state before opening a connection; do not introduce compressed air unless a specifically assessed approved procedure requires it.
Verification: Authorized operator confirms pressure release and clearing-area control.
Why this belongs in the analysis: Turning off the motor may leave a loaded line.
6. Clean and hand over
Hazard: Cement residue, loose hoses or altered braces can expose later crews.
Control: Collect washout by the site method, clean without uncontrolled dust and restore clear access. Leave wall support in place and communicate grout and access status.
Verification: Supervisor checks residue, hoses and wall support at handover.
Why this belongs in the analysis: Cleanout must not compromise wall stability.
What does a useful control look like?
| Needs improvement | More useful for this scenario |
|---|---|
| Be careful around the equipment. | Operator checks equipment, pressure rating, guards, couplings and required restraints against the model instructions. Remove defective components from service. |
| Check the area before starting. | Masonry supervisor confirms wall support, limited-access arrangements and the released grout sequence. Hold pumping for unresolved wall or access conditions. |
Decisions that change the analysis
Does a masonry wall example cover grout pumping?
No. That example includes mortar mixing and laying CMU but excludes grout pumping. Pump setup, pressurized hose handling and blockage release are the new tasks here.
What must be recorded before this example is used on a job?
Replace the scenario with the actual work, identify additional hazards with the crew, and record the applicable instructions, responsible people, inspection findings, unresolved actions and required authorization. A planned verification is not an inspection result.
Agree when the crew will pause
- Wall release or placement sequence is unclear.
- Pressure response, connections or hose behavior changes.
- Communication fails, a blockage appears or wall support is disturbed.
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
- Actual pump operation, pressure release and blockage method.
- Wall support boundaries, cement contact prevention and receiver/operator communication.
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 be used as a JSA?
Use the Task | Hazard | Control structure if it meets the employer’s format. Adapt the boundaries, controls, verification and records to the actual job.
Does this provide a completed USACE AHA?
No. Use the project’s required AHA process, risk method, supporting fields and acceptance requirements. The existing formwork AHA explains the additional structure.
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
- OSHA 1926.706 Masonry construction
- OSHA 1926.702 Concrete equipment and tools
- OSHA 1926.21 Safety training and education
Original worked example developed for the stated scenario. Primary references support the planning framework; the actual equipment manual, product instructions and project design must supply applicable operating and acceptance criteria. Use actual equipment instructions and site requirements alongside these references. Reference review: October 9, 2026.