| Step | Potential Hazard | Control |
|---|---|---|
| Assess work area and traffic conditions | Motorists approaching work zone, limited sight distance, crew stepping into open travel lanes | Set cones, signs, and barriers according to MUTCD; use flaggers or a pilot vehicle if needed; assign a lookout to monitor oncoming traffic |
| Inspect tools, materials, and equipment | Damaged posts, bent W beam sections, malfunctioning post driver, hydraulic leaks | Check all guardrail components, torque wrenches, post drivers, augers, and cutting tools; remove unsafe equipment from service |
| Don required PPE | Struck by hazards, cuts from metal edges, flying debris | Wear full PPE before beginning installation or repair work |
| Remove damaged guardrail sections | Sharp metal edges, tension release, falling components | Loosen bolts gradually, support W beam sections during removal, watch for spring loaded components, maintain solid footing |
| Mark and prepare post locations | Underground utility strikes, uneven terrain | Verify utility locates, mark post positions carefully, level the work area if possible, maintain safe distance from embankment edges |
| Install or remove posts | Equipment pinch points, flying debris, vibration exposure | Use post drivers or augers properly, keep hands clear of driving path, maintain stable footing, keep crew clear of equipment swing zones |
| Set guardrail height and alignment | Strains from lifting, incorrect height or offset, misaligned rail causing future hazards | Use two people to lift W beam sections, support while bolting, confirm height and lateral offset match standards |
| Bolt W beam sections to posts | Pinch points, cuts from metal edges | Wear gloves, maintain firm grip on hardware, tighten bolts to required torque, keep hands clear of tight gaps |
| Connect rail sections and terminals | Misalignment, loose hardware, improper terminal installation | Follow manufacturer specifications, verify impact head or terminal meets approved standards, check bolt tightness |
| Clean up old hardware and materials | Cuts from sharp metal, trip hazards, roadside debris | Collect scrap metal, bolts, and old posts; dispose properly; sweep work area to remove debris |
| Final inspection | Improper installation creating roadside hazard | Verify rail height, overlap direction, torque on hardware, proper alignment, and terminal condition before leaving site |
| Remove traffic control | Worker exposure to traffic during takedown | Remove cones and signs only after ensuring all tools, materials, and crew are clear of the roadway; use lookout during takedown |
Hard hat
Safety glasses or face shield
High visibility vest
Cut resistant gloves
Steel toe boots
Hearing protection when operating powered equipment
Long pants and long sleeves
Always have a complete, well-stocked first aid kit available.
JSA Category: Roadway Maintenance Operations
* The steps, hazards, and controls displayed above may be incomplete or not suit your department's needs. All job safety analyses should be a completed with frontline worker input to ensure that each potential hazard is identified and mitigated.
Please read about The Essentials Elements of a Solid Job Safety Anaylsis here.
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| Step | Potential Hazard | Control |
|---|---|---|
| Assess work area and traffic conditions | Motorists approaching work zone, limited sight distance, crew stepping into open travel lanes | Set cones, signs, and barriers according to MUTCD; use flaggers or a pilot vehicle if needed; assign a lookout to monitor oncoming traffic |
| Inspect tools, materials, and equipment | Damaged posts, bent W beam sections, malfunctioning post driver, hydraulic leaks | Check all guardrail components, torque wrenches, post drivers, augers, and cutting tools; remove unsafe equipment from service |
| Don required PPE | Struck by hazards, cuts from metal edges, flying debris | Wear full PPE before beginning installation or repair work |
| Remove damaged guardrail sections | Sharp metal edges, tension release, falling components | Loosen bolts gradually, support W beam sections during removal, watch for spring loaded components, maintain solid footing |
| Mark and prepare post locations | Underground utility strikes, uneven terrain | Verify utility locates, mark post positions carefully, level the work area if possible, maintain safe distance from embankment edges |
| Install or remove posts | Equipment pinch points, flying debris, vibration exposure | Use post drivers or augers properly, keep hands clear of driving path, maintain stable footing, keep crew clear of equipment swing zones |
| Set guardrail height and alignment | Strains from lifting, incorrect height or offset, misaligned rail causing future hazards | Use two people to lift W beam sections, support while bolting, confirm height and lateral offset match standards |
| Bolt W beam sections to posts | Pinch points, cuts from metal edges | Wear gloves, maintain firm grip on hardware, tighten bolts to required torque, keep hands clear of tight gaps |
| Connect rail sections and terminals | Misalignment, loose hardware, improper terminal installation | Follow manufacturer specifications, verify impact head or terminal meets approved standards, check bolt tightness |
| Clean up old hardware and materials | Cuts from sharp metal, trip hazards, roadside debris | Collect scrap metal, bolts, and old posts; dispose properly; sweep work area to remove debris |
| Final inspection | Improper installation creating roadside hazard | Verify rail height, overlap direction, torque on hardware, proper alignment, and terminal condition before leaving site |
| Remove traffic control | Worker exposure to traffic during takedown | Remove cones and signs only after ensuring all tools, materials, and crew are clear of the roadway; use lookout during takedown |
Hard hat
Safety glasses or face shield
High visibility vest
Cut resistant gloves
Steel toe boots
Hearing protection when operating powered equipment
Long pants and long sleeves