Trade size alone does not establish a permissible bender and conduit combination. Match conduit type, wall and actual tool rating. Substituted conduit requires another check, even when a fitting accepts its end.
This reference material was written and revised with AI. It has not been verified or approved by a professional. Review by a suitably qualified professional and required site approval are necessary before field use.
Stop before proceeding
Hold for unknown conduit/tool compatibility, unverified supports or access, slipping tube, damaged blades, cracked or flattened bends, suspected concealed services or moving joints. Do not force a damaged tube into a fitting.
1. Legal and technical scope
For construction installation, apply 1926.405 raceway continuity, connections and abrasion protection and the other applicable electrical provisions. Conduit selection, support spacing, bonding and fittings also depend on the approved design, product instructions and the locally adopted electrical code edition. A manufacturer hand-bender rating is a product limit, not an electrical installation approval.
Confirm whether federal OSHA or an OSHA-approved State Plan covers this employer and worksite; state requirements and public-sector coverage can differ. Apply the task-specific provisions and limitations identified above.
| Basis | Application |
|---|---|
| OSHA 29 CFR 1926.405 | Metal raceway continuity/connections and conductor entry protection; apply actual wiring-method scope. |
| Greenlee 840A hand bender | Official product scope identifies 1/2-inch EMT. Do not apply this rating to every conduit type or substitute for the actual tool manual. |
| OSHA State Plans | Official overview of federal and State Plan jurisdiction and differing public-sector coverage, checked 2026-10-13. Individual state rules require a site-specific check. |
2. Scope and required inputs
Included scope
Match listed conduit and hand tools, cut with a hand hacksaw, deburr, hand-bend and install exposed raceway into planned supports, fittings and boxes. Elevated access must be separately selected and inspected.
Separate assessment
Wire pulling, live circuits, alterations to existing energized systems, powered benders, pipe threaders, abrasive saws, core drilling and hazardous-location installations are separate scopes.
| Input | Evidence needed |
|---|---|
| Match route and tube | Drawing and route; Type wall and size; Nearby circuits; Fitting instructions. |
| Cut and deburr | Blade and grip; Inside outside edges; Offcut support; Hand clearance. |
| Install supports | Supports and boxes; Joint assembly; Access and reach; Below-work exclusion. |
| Clean and handoff | Clean work area; Inspection record; Route and receiver; Open-end protection. |
No site measurements, equipment manuals for the actual installation, inspection records or signed technical approvals were supplied. Confirm the applicable requirements and actual product instructions before use; record each criterion with its units, source and equipment or work-area ID.
3. Eight-stage JSA
| Job stage | Hazards and effects | Failure factors | Technical and procedural controls | Site verification | P | S | R | A |
|---|---|---|---|---|---|---|---|---|
| 1. Match route and tube | 1. Electrical contact2. Wrong tube breaks3. Service damage4. Wrong fitting | 1. Circuit misidentified2. Type unchecked3. Hidden services4. Trade size assumed | 1. Verify route boundary2. Match conduit type3. Locate services4. Match listed fittings | 1. Drawing and route2. Type wall and size3. Nearby circuits4. Fitting instructions | ||||
| 2. Prepare bench and move | 1. Long tube strikes2. Tube rolls3. Offcut drops4. Hand strain | 1. Ends uncontrolled2. Bench unstable3. No end support4. Awkward carry | 1. Plan full swing path2. Secure bench and vice3. Support tube ends4. Use handling aid | 1. Travel and swing2. Vice condition3. Support positions4. Tube length and weight | ||||
| 3. Cut and deburr | 1. Saw cut injury2. Burr puncture3. Eye injury4. Tube slips | 1. Hand at cut2. Inside burr missed3. Chips exposed4. Loose clamping | 1. Clamp and support2. Deburr both edges3. Use eye protection4. Check blade and vice | 1. Blade and grip2. Inside outside edges3. Offcut support4. Hand clearance | ||||
| 4. Hand bend | 1. Tube end strikes2. Tube splits3. Worker falls4. Bend collapses | 1. Swing path occupied2. Wrong bender3. Poor footing4. Force correction | 1. Clear full radius2. Use matched bender3. Keep stable stance4. Inspect bend shape | 1. Tool tube match2. Swing exclusion3. Footing and handle4. Flattening and cracks | ||||
| 5. Install supports | 1. Conduit falls2. Finger pinched3. Access fall4. Box joint fails | 1. Support removed early2. Joint hand-held3. Overreach4. Fixing unverified | 1. Maintain tube support2. Keep pinch clearance3. Use planned access4. Verify fixing substrate | 1. Supports and boxes2. Joint assembly3. Access and reach4. Below-work exclusion | ||||
| 6. Inspect raceway | 1. Insulation damage2. Bond path lost3. Wrong route4. Water ingress | 1. Burr overlooked2. Joint loose3. Drawing ignored4. Entry incomplete | 1. Inspect bore and ends2. Check required bonding3. Match route drawing4. Finish suitable entries | 1. Bore and bends2. Fittings and bonding3. Route acceptance4. Entry protection | ||||
| 7. Hold deformation | 1. Defect concealed2. Tube drops3. Repeated damage4. Live exposure | 1. Tube forced straight2. Support unresolved3. Tool not changed4. Circuit assumed dead | 1. Identify held section2. Restore support safely3. Correct tool match4. Reassess circuit boundary | 1. Bend fault cause2. Support correction3. Replacement record4. Electrical access state | ||||
| 8. Clean and handoff | 1. Offcut puncture2. Unapproved pulling3. Label lost4. Exposed sharp end | 1. Chips left2. Hold not conveyed3. Route ID absent4. End unprotected | 1. Collect with tools2. Transfer inspection holds3. Identify route4. Protect open ends | 1. Clean work area2. Inspection record3. Route and receiver4. Open-end protection |
P = likelihood; S = severity; R = risk under the site method; A = the site-defined acceptance/authorization decision. Complete only after actual assessment. Blank cells and checklist prompts are not completed inspections.
4. Fictional scenario and failure mechanisms
Retained AI-generated educational illustration from the source edition; not a real incident photograph, approved installation drawing or evidence of equipment suitability.
The scenario and record comparisons are fictional teaching examples, not records of real incidents, measurements, inspections, signatures or approvals.
| Item | Fictional scenario |
|---|---|
| Initial | A hand-bent conduit is ready for installation. |
| Change | The inside of the bend is visibly flattened. |
| Failure | The installer accepts it because the end fits the coupling. |
| Outcome | A damaged raceway may injure conductors or fail the installation criteria. |
| Barrier | Hold and identify the tube, verify conduit/tool compatibility and replace or remake it to the applicable acceptance criteria. |
Why the controls matter
Trade size alone does not establish a permissible bender and conduit combination. Match conduit type, wall and actual tool rating. Substituted conduit requires another check, even when a fitting accepts its end.
A helper hand is not an offcut support. Secure the tube and support the cut end before sawing. Keep people clear of the full long-tube swing path during handling and bending.
Inspect inside and outside cut edges, bend shape, joints and box entries before wire pulling. A straight appearance does not demonstrate electrical continuity or acceptable bonding. Transfer inspection results and held sections to the electrical receiver.
Decision sequence
| Step | Decision |
|---|---|
| Known | The inside of the bend is visibly flattened. |
| Unknown | Actual condition, extent of damage and suitability of supports and boxes, joint assembly remain to be established. |
| Hold | The installer accepts it because the end fits the coupling. |
| Evidence | Link supports and boxes, joint assembly, access and reach, below-work exclusion, bend fault cause, support correction to the affected equipment or work area. |
| Next | Hold and identify the tube, verify conduit/tool compatibility and replace or remake it to the applicable acceptance criteria. |
5. Conditional decisions and common errors
| Condition | Action | Evidence | Proceed when |
|---|---|---|---|
| Tool mismatch | Hold bending | Conduit and tool identification | Combination permitted |
| Flattened bend | Segregate tube | Bend acceptance review | Accepted replacement |
| Loose support | Maintain temporary support | Substrate and fixing check | Load path verified |
| Ready for pulling | Inspect full route | Burr joint and bonding record | Route released |
Similar appearance, different evidence
The scenario and record comparisons are fictional teaching examples, not records of real incidents, measurements, inspections, signatures or approvals.
| Comparison | Supported decision | Insufficient basis |
|---|---|---|
| Condition | Conduit and tool identification | Tool mismatch has not been resolved. |
| Evidence | Substrate and fixing check | A photograph or a completed-looking task without the relevant inspection record. |
| Release | Route released | Completion of one step does not release the excluded tasks in section 2. |
6. Roles and responsibilities
| Role | Responsibility |
|---|---|
| Work supervisor | Assign the task boundary, stop authority, interfaces and emergency communication for manual metal conduit cutting, bending and installation. |
| Technical lead | Confirm Drawing and route; Type wall and size; Nearby circuits; Fitting instructions. Resolve design and manufacturer limits before work. |
| Authorized crew | Apply Blade and grip; Inside outside edges; Offcut support; Hand clearance. Stop when the working arrangement changes. |
| Inspector / receiving lead | Review Supports and boxes; Joint assembly; Access and reach; Below-work exclusion. Transfer Clean work area; Inspection record; Route and receiver; Open-end protection. |
Role labels allocate responsibilities; they do not confer a legal qualification. Verify the competence, training and authority required for the actual task.
Record and handoff perspective
| Stage | Record controls | Verification |
|---|---|---|
| Match route and tube | 1. Record drawing and route2. Record type wall and size3. Record nearby circuits | 1. Type wall and size2. Nearby circuits3. Fitting instructions |
| Cut and deburr | 1. Record blade and grip2. Record inside outside edges3. Record offcut support | 1. Inside outside edges2. Offcut support3. Hand clearance |
| Hand bend | 1. Record tool tube match2. Record swing exclusion3. Record footing and handle | 1. Swing exclusion2. Footing and handle3. Flattening and cracks |
| Install supports | 1. Record supports and boxes2. Record joint assembly3. Record access and reach | 1. Joint assembly2. Access and reach3. Below-work exclusion |
| Hold deformation | 1. Record bend fault cause2. Record support correction3. Record replacement record | 1. Support correction2. Replacement record3. Electrical access state |
| Clean and handoff | 1. Record clean work area2. Record inspection record3. Record route and receiver | 1. Inspection record2. Route and receiver3. Open-end protection |
7. Hold points and record comparison
| Hold point | Evidence before release | Actual record |
|---|---|---|
| HP-0 Start | Match listed conduit and hand tools, cut with a hand hacksaw, deburr, hand-bend and install exposed raceway into planned supports, fittings and boxes. Elevated access must be separately selected and inspected. | |
| HP-1 Prepare bench and move | Travel and swing; Vice condition; Support positions; Tube length and weight | |
| HP-2 Hand bend | Tool tube match; Swing exclusion; Footing and handle; Flattening and cracks | |
| HP-3 Inspect raceway | Bore and bends; Fittings and bonding; Route acceptance; Entry protection | |
| HP-4 Clean and handoff | Clean work area; Inspection record; Route and receiver; Open-end protection |
These are internal hold points, not issued permits. Recheck affected points after a change, fault or shift handoff; link the actual approval record.
Record comparison
The scenario and record comparisons are fictional teaching examples, not records of real incidents, measurements, inspections, signatures or approvals.
The boxes are static record prompts, not interactive or saved approvals. A tick does not establish suitability or permission to restart. Record the evidence, person, time and unresolved issues; retain the change history.
| Record | Insufficient | Record checklist |
|---|---|---|
| Match route and tube | "Checked" without target, criteria or result | □ Drawing and route□ Type wall and size□ Nearby circuits□ Fitting instructions |
| Cut and deburr | "Checked" without target, criteria or result | □ Blade and grip□ Inside outside edges□ Offcut support□ Hand clearance |
| Install supports | "Checked" without target, criteria or result | □ Supports and boxes□ Joint assembly□ Access and reach□ Below-work exclusion |
| Clean and handoff | "Checked" without target, criteria or result | □ Clean work area□ Inspection record□ Route and receiver□ Open-end protection |
8. Site checklist and emergency response
| Check | Result | Person / action |
|---|---|---|
| □ Match route and tube: Drawing and route | ||
| □ Prepare bench and move: Travel and swing | ||
| □ Cut and deburr: Blade and grip | ||
| □ Hand bend: Tool tube match | ||
| □ Install supports: Supports and boxes | ||
| □ Inspect raceway: Bore and bends | ||
| □ Hold deformation: Bend fault cause | ||
| □ Clean and handoff: Clean work area | ||
| □ Emergency access and handoff restrictions |
Stop work
Hold for unknown conduit/tool compatibility, unverified supports or access, slipping tube, damaged blades, cracked or flattened bends, suspected concealed services or moving joints. Do not force a damaged tube into a fitting.
Emergency response
Keep people clear of fallen or electrically suspect conduit. Request safe shutdown and isolation by authorized electrical personnel. Do not touch a person or tube still exposed to electricity; activate site response and call 911 as required.
9. Sources and review limits
Public-source review: 2026-10-13. Official regulation pages and specific technical references are distinguished below; no agency or manufacturer has approved this content.
| Source | Reviewed scope and limitation |
|---|---|
| OSHA 29 CFR 1926.405 | Metal raceway continuity/connections and conductor entry protection; apply actual wiring-method scope. |
| Greenlee 840A hand bender | Official product scope identifies 1/2-inch EMT. Do not apply this rating to every conduit type or substitute for the actual tool manual. |
| OSHA State Plans | Official overview of federal and State Plan jurisdiction and differing public-sector coverage, checked 2026-10-13. Individual state rules require a site-specific check. |
No site measurements, equipment manuals for the actual installation, inspection records or signed technical approvals were supplied. Confirm the applicable requirements and actual product instructions before use; record each criterion with its units, source and equipment or work-area ID.
10. PDF guidance and FAQ
PDF A covers basic task controls; B focuses on technical failures; C covers supervision, records and handover. The article has eight stages with four items per main cell; each PDF has six key stages with three items per main cell. P/S/R/A, measurements, confirmations and signatures remain blank for actual site assessment.
Content group
jsa-metal-conduit-cut-bend-install
Does matching trade size prove compatibility?
No. Match conduit type and wall with the actual tool instructions.
Can wire pulling remove burrs?
No. Remove and inspect burrs before pulling conductors.
Is one support spacing universal?
No. Use the actual raceway system, design and applicable code/product requirements.
Does fitting engagement prove bonding?
No. Verify permitted fittings, assembly and the required continuity/bonding inspection.
Has a professional approved this JSA?
This reference material was written and revised with AI. It has not been verified or approved by a professional. Review by a suitably qualified professional and required site approval are necessary before field use.
11. Revision history and authorship
This reference material was written and revised with AI. It has not been verified or approved by a professional. Review by a suitably qualified professional and required site approval are necessary before field use.
Korean source created 2026-10-08. This US edition adapts the Korean source; earlier editorial revisions do not constitute professional approval of this edition.
| Date | Edition | Change | Review status |
|---|---|---|---|
| 2026-10-08 | Korean source v1.0 | Source editorial publication or revision; retained as provenance of the Korean edition. | Editorial record only; no professional approval of this US edition. |
| 2026-10-13 | 1.0 | US localization: preserve task judgments; replace Korean legal applicability with scoped US references. | AI editorial and output checks; no professional technical approval. |