First, describe the work and worksite
A trained masonry worker will cut marked brick and CMU units using a guarded electric stationary masonry saw with its integrated continuous water system at a separated outdoor ground-level station. The actual machine’s carrier supports the units, and slurry is collected before it dries. This example follows setup, cutting, stopping and controlled cleanup. This fictional learning example describes planned controls; it records no actual inspection or work authorization.
- The selected saw, manufacturer-approved diamond blade, carrier, stand and power supply are suitable for the identified units and planned straight cuts.
- The employer fully implements the stationary-masonry-saw Table 1 water method and actual maintenance instructions, with competent-person oversight and assessed other exposure controls.
- Masonry-saw coverage is bounded to this stationary wet method; 238140-11 is partial because handheld cutting, splitters, dry methods and cutting installed walls are excluded.
Questions before work
- Can each unit be supported on the carrier with hands outside the cutting zone throughout its travel?
- What verifies continuous integrated water delivery before and during every cut?
- How are electrical connections, slurry collection and stopped-motion/isolation checks kept effective together?
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. Release the station and unit cuts
Hazard: An unstable stand, overcrowded cut path or incompatible unit can expose workers to moving equipment and fragments.
Control: Cutting lead selects released marked cuts suited to the actual stationary saw and blade. Establish a stable station and carrier travel zone away from deliveries, with room to stage manageable units and remove finished pieces. Reject oversize work that cannot be supported or controlled as the manual requires.
Verification: Lead checks machine support, unit dimensions, marked cuts and clear operating space.
Why this belongs in the analysis: A masonry unit is not safe to cut merely because it can touch the blade.
2. Inspect and set up with power isolated
Hazard: Damaged blades, open guards or unexpected starting can cause contact injury and blade failure.
Control: Disconnect and secure the saw’s supply under its actual isolation instructions before setup. Inspect the compatible blade, mounting, enclosure, drive guarding, carrier, stand and controls. Complete only the permitted adjustments, remove keys and tools and quarantine defects before the machine is connected for pre-use checks.
Verification: Operator records blade/guard/carrier findings and verifies the setup safe state.
Why this belongs in the analysis: Guard condition and unit support must be checked separately from the water system.
3. Establish water, power and slurry control
Hazard: Lost water can release silica; wet connections or pooled slurry can create shock and slips.
Control: Connect the actual integrated system and verify continuous water delivery to the blade using the manufacturer’s criteria. Arrange the required protected electrical supply and keep connections clear of water. Contain slurry and preserve dry secure footing; the silica competent person checks the selected Table 1 implementation before production cuts.
Verification: Operator confirms blade water delivery and the lead checks power, footing and containment.
Why this belongs in the analysis: Water must reach the cutting surface rather than only wetting the surrounding station.
4. Cut units on the supported carrier
Hazard: Hands, loose clothing or unstable stock can enter the blade path; fragments and noise expose others.
Control: Use the manual’s carrier and unit-positioning method with hands outside the cutting area, intact guards and suitable assessed protection. Feed at the permitted rate without forcing or twisting the unit. Keep bystanders outside the station and stop immediately for binding, abnormal response, shifting stock or lost water delivery.
Verification: Operator watches water and unit control during travel; the lead maintains station separation.
Why this belongs in the analysis: A clear pre-use check does not guarantee the controls remain effective during the cut.
5. Stop before removing faults or adjusting
Hazard: Reaching past a coasting blade or treating a switch as isolation can cause severe contact injury.
Control: Use the actual stopping procedure and wait for complete blade motion to cease before the permitted unloading action. Disconnect and secure power before jam clearing, blade work or hazardous adjustments. Correct water or carrier faults in the required safe state and repeat relevant checks before restart.
Verification: Operator verifies stopped motion and required isolation before entering hazardous parts.
Why this belongs in the analysis: Normal unloading and fault intervention need different access and energy checks.
6. Collect residue and secure the station
Hazard: Dried slurry can become airborne silica and abandoned cut pieces can create sharp-edge or trip exposure.
Control: Clean the stopped, isolated equipment by its approved method. Collect slurry while wet and handle it under site waste arrangements; use suitable wet or HEPA methods for remaining residue. Do not dry sweep or blow this station clean. Secure blades, useful stock and the supply, and transfer defects or operating restrictions.
Verification: Cutting lead checks residue collection, electrical/tool state and clear access before handover.
Why this belongs in the analysis: The dust-control method must extend beyond the last powered cut.
What does a useful control look like?
| Needs improvement | More useful for this scenario |
|---|---|
| Spray the blocks occasionally to reduce dust. | Use the actual integrated system that continuously feeds water to the blade, verify flow during cutting and stop when delivery fails. |
| Switch off and reach in to clear the carrier. | Wait for blade motion to stop and secure the disconnected supply before hazardous adjustment or jam clearing, then recheck the corrected setup. |
Decisions that change the analysis
Can the walk-behind concrete-saw example substitute here?
No. That operator moves an engine-powered saw through a ground slab. This worker feeds discrete units on a stationary carrier with different hand locations, guarding, wet electrical and slurry arrangements. Both need controls matched to the actual tool and silica method.
What must the crew record for actual use?
Record the actual work boundary, equipment and materials, responsible people, applicable criteria, control checks and unresolved actions. Keep changed conditions on hold, communicate restrictions to affected crews and obtain the required project authorization before work.
Agree when the crew will pause
- Blade, guard, carrier, stand or protected electrical arrangement is defective or unsuitable for the unit.
- Water delivery fails, stock moves, the blade binds or slurry defeats safe footing and containment.
- Work changes to dry cutting, a handheld saw, installed masonry or a unit the carrier cannot control.
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
- Actual saw instruction covering carrier travel, guarding, blade compatibility, water setup, stopping and safe isolation for adjustments.
- Applicable silica-control method and housekeeping, wet electrical protection, assessed eye/hearing protection and defect reporting.
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 sequence to the employer’s JSA format and actual worksite. Name the people who will check controls and record their findings; this learning example supplies no completed field inspection.
What changes if the project requires an AHA?
Use the governing AHA format, risk method, supporting records and acceptance process. The published formwork AHA illustrates that additional structure. Add the actual competencies, inspections and project reviews rather than assuming a renamed JHA meets those requirements.
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
- MK Diamond MK-2000 electric masonry saw owner’s manual
- OSHA 1926.1153 Silica Table 1 and housekeeping
- OSHA 1926.300 Hand and power tools
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.