Non-Shrink Grouting AHA (Activity Hazard Analysis / Job Hazard Analysis)

Updated 2026-06-23

A Non-Shrink Grouting AHA (Activity Hazard Analysis / Job Hazard Analysis) is the plan that keeps the crew doing non-shrink grouting safe around the under-baseplate and equipment grouting access, from the caustic cement contact and mixing dust, and through the flowable placement and confined ergonomics. Non-shrink grouting places non-shrink grout under baseplates and equipment — combining the under-baseplate and equipment-grouting-access hazard, the caustic-cement-contact and mixing-dust hazard, and the flowable-placement and confined-ergonomics hazard. This guide walks through building a Non-Shrink Grouting AHA that names the under-baseplate/equipment- grouting-access, caustic-cement-contact/mixing-dust, and flowable-placement/confined-ergonomics hazards and assigns the access, contact/dust, and placement controls that hold up in the field.

Why non-shrink grouting needs its own AHA

Non-shrink grouting is the placement of non-shrink grout — a cement-based (or sometimes epoxy) grout formulated not to shrink as it cures — most characteristically used to grout under equipment baseplates, machinery bases, column base plates, anchor bolts, and bearing plates, where the grout must fully fill the space and maintain contact (hence non-shrink) to transfer load. This closes the grouting cluster and the batch. The defining feature is the characteristic application: grouting under baseplates and equipment, which puts workers in the awkward, confined access around and under equipment bases, with the caustic cement contact and mixing dust of cement-based grout, placing a flowable grout that must fully fill the space. The hazards combine the under-baseplate and equipment-grouting-access (non-shrink grout is characteristically placed under baseplates and equipment — the access hazard (working around and under equipment bases, machinery, and baseplates — awkward, confined, and around the equipment)), the caustic-cement-contact and mixing-dust (the cement-based non-shrink grout — the caustic-contact hazard (cement burns) and the mixing dust/silica), the flowable-placement and confined-ergonomics (placing the flowable non-shrink grout so it fully fills the space under the baseplate — the placement and the confined/awkward ergonomics), and the epoxy-type/slip. The under-baseplate/equipment-grouting-access and the caustic-cement-contact/mixing-dust justify a dedicated AHA.

Breaking non-shrink grouting into steps

The steps for a Non-Shrink Grouting AHA follow the work:

• Prepare the baseplate/equipment area and access
• Mix the non-shrink grout (dust control, per the type)
• Place the flowable grout under the baseplate (contact protection)
• Ensure the grout fully fills the space
• Manage the access, contact, and dust hazards
• Finish/tool the grout edges
• Clean up and allow to cure
• Complete

Each step carries a hazard, and the under-baseplate/equipment-grouting-access, the caustic-cement-contact/mixing- dust, and the flowable-placement/confined-ergonomics are where the most significant risks concentrate.

The hazards step by step

Under-baseplate and equipment-grouting-access

Non-shrink grout is characteristically placed under baseplates and equipment — the access hazard (working around and under equipment bases, machinery, and baseplates — awkward, confined, and around the equipment). The controls are safe access for the under-baseplate/equipment grouting (working around and under equipment bases is awkward and confined — safe access, confined-space procedures where applicable, and coordination with the equipment/ machinery, including ensuring the equipment is stable/secured and any energy is controlled where grouting around installed equipment), and the access controls. The under-baseplate/equipment-grouting-access is a defining hazard — non-shrink grouting works in awkward, confined access under equipment. (These follow the equipment-access fundamentals.)

Caustic-cement-contact and mixing-dust

The cement-based non-shrink grout — the caustic-contact hazard (cement burns) and the mixing dust/silica. The controls are preventing skin contact with the caustic cement-based non-shrink grout (waterproof/chemical-resistant gloves, protective clothing — cement-based non-shrink grout is caustic, causing cement burns), dust control when mixing (the dry cement-based material creates silica-containing dust — respiratory protection), eye protection, and the contact/dust controls. The caustic-cement-contact/mixing-dust is a defining hazard — cement-based non-shrink grout is caustic and its mixing creates silica dust. (These follow the cement-contact and silica fundamentals.)

Flowable-placement and confined-ergonomics

Placing the flowable non-shrink grout so it fully fills the space under the baseplate — the placement and the confined/awkward ergonomics. The controls are controlled placement of the flowable grout (placing/pouring the flowable grout so it flows under and fully fills the space — the placement technique), managing the confined/ awkward ergonomics (placing grout under baseplates and equipment in awkward, low, confined positions), and the placement/ergonomic controls. The flowable-placement/confined-ergonomics is a defining hazard. (These follow the grout-placement and ergonomic fundamentals.)

Epoxy-type/slip

The epoxy-type and slip (epoxy non-shrink grouts, spilled grout) carries the epoxy/slip hazard. The controls are epoxy controls where using epoxy non-shrink grout (skin/respiratory sensitizers, ventilation — some non-shrink grouts are epoxy-based), slip awareness, and the epoxy/slip controls. (These follow the epoxy-handling fundamentals.)

A simple Non-Shrink Grouting AHA structure

Under-equipment access control and cement-contact/dust management

A Non-Shrink Grouting AHA centers on under-equipment access control and cement-contact/dust management. The under-equipment access control addresses the characteristic under-baseplate work — controlled by safe access for the under-baseplate/equipment grouting (confined-space procedures where applicable, coordination with the equipment including stability and energy control where grouting around installed equipment). The cement-contact/ dust management addresses the caustic grout and the mixing — controlled by preventing skin contact with the caustic cement-based non-shrink grout (chemical-resistant gloves, protective clothing) and dust control when mixing (respiratory protection against silica). And the flowable placement, epoxy types, and slip get placement, epoxy, and slip controls. An AHA built on under-equipment access control and cement-contact/dust management, with placement controls, addresses the hazards that define non-shrink grouting.

From the field: what actually goes wrong

In fourteen years across federal, heavy civil, and industrial projects, non-shrink grouting places non-shrink grout under baseplates and equipment, and it closes the grouting cluster and this batch. Its hazards are shaped by its characteristic application — grouting under equipment baseplates and machinery bases. The under-baseplate and equipment-grouting-access hazard is a primary defining concern — non-shrink grout is most characteristically used to grout under equipment baseplates, machinery bases, column base plates, anchor bolts, and bearing plates (the "non-shrink" property matters there because the grout must fully fill and stay in contact to transfer load), and this puts workers in the awkward, confined access around and under equipment bases: working under and around baseplates and machinery, in tight and low positions, sometimes in confined spaces, and often around installed equipment. So safe access for the under-baseplate and equipment grouting (safe access to the awkward and confined positions, confined-space procedures where applicable, and coordination with the equipment — including ensuring the equipment or machinery is stable and secured, and that any energy is controlled, where grouting around installed equipment) is the control. The under-equipment access is what characterizes and complicates non-shrink grouting.

The caustic-cement-contact/mixing-dust and the flowable-placement/confined-ergonomics are the other defining hazards, and they carry the cluster's recurring themes into this closing doc. On the projects I have run, non-shrink grout is typically cement-based, so it carries the same caustic-contact hazard as all cement grouting (cement burns from skin contact — chemical-resistant gloves and protective clothing) and the same mixing dust and silica hazard (dust control and respiratory protection when mixing the dry cement-based material), the two themes that have run through the whole grouting cluster (grouting, cementitious, dry-pack, and now non-shrink). And the flowable-placement/confined-ergonomics hazard is placing the flowable non-shrink grout so it flows under and fully fills the space under the baseplate (the placement technique), done in the awkward, low, confined positions under equipment (the ergonomic strain). Some non-shrink grouts are epoxy-based, which adds the epoxy sensitizer and ventilation concerns, and the slip from spilled grout rounds it out. This closes the grouting cluster (137–140) and Batch 14. The AHA built on under-equipment access control and cement-contact/dust management is the one that protects the non-shrink grouting crew.

The bottom line

A Non-Shrink Grouting AHA names the under-baseplate/equipment-grouting-access, the caustic-cement-contact/mixing- dust, and the flowable-placement/confined-ergonomics hazards with specific controls — safe access for the characteristic under-baseplate and equipment grouting (with equipment stability and energy control where applicable), preventing caustic cement contact and controlling silica dust when mixing (the recurring grouting- cluster themes), and controlled flowable placement in confined/awkward positions. The under-equipment access control and the cement-contact/dust management are the defining concerns. The AHA that manages both is the one that protects the crew.

Frequently asked questions

Why is under-equipment access the characteristic non-shrink grouting hazard?

Non-shrink grout is most characteristically used to grout under equipment baseplates, machinery bases, column base plates, anchor bolts, and bearing plates (the non-shrink property matters there so the grout fully fills and stays in contact to transfer load), which puts workers in the awkward, confined access around and under equipment bases — in tight, low positions, sometimes confined spaces, often around installed equipment. Controls are safe access for the under-baseplate/equipment grouting (confined-space procedures where applicable, coordination with the equipment including stability/securing and energy control where grouting around installed equipment), and the access controls.

What contact and dust hazards apply?

Non-shrink grout is typically cement-based, so it carries the caustic-contact hazard (cement burns from skin contact) and the mixing dust/silica hazard (mixing the dry cement-based material creates silica-containing dust) — the recurring themes of the grouting cluster. Controls are preventing skin contact with the caustic cement-based non-shrink grout (chemical-resistant gloves, protective clothing), dust control when mixing (respiratory protection against silica), eye protection, and the contact/dust controls.

What placement and ergonomic hazards apply?

Placing the flowable non-shrink grout so it flows under and fully fills the space under the baseplate is done in awkward, low, confined positions under equipment. Controls are controlled placement of the flowable grout (placing/pouring so it flows under and fully fills the space), managing the confined/awkward ergonomics (placing grout under baseplates and equipment in awkward positions), epoxy controls where using epoxy non-shrink grout (sensitizers, ventilation), and the placement/ergonomic controls.

What is non-shrink grouting?

Non-shrink grouting is the placement of non-shrink grout — a cement-based (or sometimes epoxy) grout formulated not to shrink as it cures — most characteristically used to grout under equipment baseplates, machinery bases, column base plates, anchor bolts, and bearing plates, where the grout must fully fill the space and maintain contact to transfer load. Because it works in awkward under-equipment access, the cement-based grout is caustic with silica-containing mixing dust, and the flowable placement is in confined positions, those hazards apply.

Related AHAs and JHAs

• Grouting AHA — the general grouting fundamentals
• Cementitious Grouting AHA — the related cement-based grouting
• Equipment Grouting JHA — the equipment-grouting fundamentals
• Turbine Alignment and Precision Grouting JHA — related precision equipment grouting

Written by Mustafa Tok, CSP, ASP, CHST — OSHA Authorized Outreach Trainer with 14+ years of international construction safety experience across federal, heavy civil, and industrial projects.