Safety Task Analysis
Card (STAC)
Training
Updated 3/2013
Pre-Task Analysis
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Pre-task Analysis is the behavior of…
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Thinking about the task to be performed
Thinking about the hazards associated with those
tasks
Thinking about ways to eliminate and control
those hazards
This Pre-task Analysis is then documented by
filling out a STAC card
Why do we do STACS?
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Eliminate injuries
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It has been proven that since the implementation of
this tool there has been a reduction in the OSHA
rate
Identify tasks from job scope
Identify hazards associated with each task
Identify ways to eliminate and control those
hazards
STACS Must Always Be filled Out
At The Job Site
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STACS should be reviewed, updated,
or re-STAC when conditions change
Change in weather
 Change in job scope
 Change in surroundings
 Etc…
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Issues and Expectations
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ISSUE
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Job with no STAC
EXPECTATION
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All Maintenance, Contractors, and Engineering
Solutions working on any job on the Dow site
must have a correct, current STAC to cover that
job. It is the responsibility of the employee, his
supervisor, and the contractor safety contact to
make sure this happens
Issues and Expectations
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ISSUE
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Same STAC card being copied day after day
EXPECTATION
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To complete an adequate job of task analysis each
individual must take a “fresh” look at each job
each day to be completed, the hazards associated
with that job and any surrounding conditions that
may impact the safety of the individual worker or
other members of the crew. This can not be
accomplished by copying yesterday’s STAC.
Issues and Expectations
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ISSUE
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STAC being filled out at the beginning of the day
and not making changes later in the day as the job
scope changes.
EXPECTATION
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Each individual’s STAC must be current and
identify those tasks being accomplished at any
given time during the day. As tasks are added or
changed the STAC must reflect those additions or
changes.
Issues and Expectations
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ISSUE
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Foreman/Crew leader signing off on poor STAC
cards: tasks too broad, hazards not specific, little or
no effort to identify eliminations or controls.
EXPECTATION
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It is the responsibility of the Foreman/Crew leader
to verify the STAC is of good quality before
signing/approving the STAC card.
Foreman/Superintendent
Accountability
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Foreman/Superintendent will be held
accountable for the quality of their employees’
STAC cards. STAC cards are encouraged to
be turned in to foreman/crew leader at the end
of shift and given to the Safety Contact and
retained for audit purposes. STAC cards
should be kept by the company for 7 days.
Unacceptable Observations
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An unacceptable observation will be issued to
your company for the following, but not
limited to:
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Task being performed is not listed on STAC
No/wrong date on STAC
Foreman/Crew Leader not signed off on STAC
Employee conducting hands on work not having
STAC
No STAC insert or wrong date on STAC insert
Task too broad
HOW TO COMPLETE
A STAC
Outside of STAC
Outside of STAC
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Safety Task Analysis Card (STAC)
I commit to follow the rules, policies and procedures
under all circumstances and will not take any shortcuts
for any reason.
Today's Date:______________ Start Time:_____________
My Name: _________________________________________
My Company Name: _______________________________
My Foreman/Crew Leader/Coach:___________________
My Job Location: __________________________________
I listed all co-workers in my crew and before
beginning work I will discuss hazards, eliminations
and controls so we do not get injured or cause any
incidents.
___________________________________________________
___________________________________________________
At Risk Employee Only Information: Yes or No
I started the At-Risk program on: Date ________________
I have completed the At-Risk test: Date________________
Job Site Emergency Plan:
1. What Chemicals am I working around:
(List) ____________________________________________
____________________________________________________
2. What is the wind direction: (check often)
7am/pm ___________ 9:30am/pm______
12:30am/pm _______ 2am/pm_________
3. Evacuation assembly point is______________________
4. Nearest eye wash/shower station is:________________
5. Nearest intercom or means of communication
Location is:______________________________________
____________________________________________________
6. Control Room or Work Authorizer’s Phone # is:
____________________________________________________
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Initial Information
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At Risk Information
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Worker must fill out all
chemicals in the working area
that he/she may have the
potential for exposure to
Wind Direction
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This section is ONLY for “at
risk” employees. If your are not
an “at risk” employee just circle
“No”
Job Site Emergency Plan
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Worker must have correct date
and time, specific job location,
and members of co-workers in
the crew
The worker should check wind
direction frequently and note on
STAC card (could be after breaks
or lunch or obvious weather
change)
Phone Number
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The worker should list the
control room or the work
authorizer’s phone number
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Outside of STAC
Immediately report any incident or emergency
situation to the facility you are working at!
In plant phone / Emergency call: 66666
Non-Emergency: 82112 Outside plant location phone /
979-238-2112
Chemical Emergency
Communication
GAS RELEASE – Continuous Blast -------------------------Cancels safe work permits. Sounded only by the department
at the point of release
ALERT – Series of Short Blasts -- -- -- -- -- -Evacuate according to your permits
EVACUATE – Series of 3 Short Blasts --- --- --Evacuate according to your Unit Emergency Plan
ALL CLEAR – Series of 3 Long Blasts ------ ------ -----Return to work area and have all work permits renewed before
work is resumed
Level Alert System
Chemical Emergency Communication
Impact – A Safety or Health Hazard
Level 0
An incident is in progress, which can be handled with the
boundaries of the block/unit. No impact is anticipated
outside of the block/unit.
Level 1
An incident is in progress, which can be handled within the
boundaries of the plant site. No impact is anticipated
outside of the site.
Level 2
An incident is in progress, which appears that it can be
handled within the boundaries of the plant site. However,
the community could be affected.
Level 3
An incident is in progress, which will affect areas outside of
the plant site. A full emergency condition exists for areas
outside of the site.
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Emergency Information
Provided for Reference
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Emergency/nonemergency phone
numbers for
inside/outside plant
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Chemical Emergency
Horn Information (Gas
Release, Alert, Evacuate,
All Clear)
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Chemical Emergency
Impact Levels (0,1,2,3)
Outside of STAC
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Communication
What hazards from your job need to be communicated to
other workers in the area:
List:________________________________________________
____________________________________________________
____________________________________________________
Personal Protective Equipment
What is the required PPE that I will need to use to protect
me from being injured:
List:________________________________________________
___________________________________________________
Mobile Equipment Hazards
List all mobile equipment you have been trained for and will
be operating on this job: (Forklift, Aerial Lift, Truck, etc…)
___________________________________________________
___________________________________________________
____________________________________________________
What are the hazards in the area that I am operating this
equipment? (piperack, power lines, critical equipment,
uneven surfaces, etc…)
____________________________________________________
____________________________________________________
Hand Safety
These are my potential hand hazards and this is what I will
do to mitigate these hazards: ____________________________
____________________________________________________
____________________________________________________
What is your reason for working safe today?
___________________________________________________
____________________________________________________
Foreman/Crew leader/Coach reviewing and
approving STAC:
Signature:_________________________ Date:___________
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Communication
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Personal Protective Equipment
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Worker should list potential hand hazards
and list his/her plans to mitigate these
hazards
Making it Personal
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For any mobile equipment being used in
the task the worker should be fully trained
and listed in this section
Workers should list any hazards in the area
of using this equipment
Hand Safety
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Worker should list ALL PPE required to
perform their task safely
Mobile Equipment Hazards
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Worker should list any hazards that could
come into play with other workers in the
area. (ex. Overhead work, hydroblasting,
hot work, etc)
Worker should note his/her reason for
working safely today
STAC Card Approval
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Foreman/Crew leader/Coach should sign
here once he has reviewed the card and
agrees it is a quality STAC card
Inside of STAC
Inside of STAC
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List Job Description: __________________________
List 3-4 specific job tasks below and also address the
special emphasis
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Task 1.
______________________________________________
______________________________________________
______________________________________________
______________________________________________
Task 2.
______________________________________________
______________________________________________
______________________________________________
______________________________________________
Task 3.
______________________________________________
______________________________________________
______________________________________________
______________________________________________
Task 4.
______________________________________________
______________________________________________
______________________________________________
______________________________________________
Special Emphasis:
_____________________________________________
______________________________________________
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_______________________________________________________
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Worker must list his/her job
description
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Worker must list 3-4 SPECIFIC
job tasks
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Examples of Specific Tasks
 Cut 1” rebar with metal
hacksaw
 Cut 12” alloy pipe with band
saw from existing pipe rack
Examples of too broad of tasks
 Cut rebar/tie rebar
 Cut pipe, grind pipe
Special Emphasis
 Worker will be required to
address the special emphasis
when provided one by
Contractor Safety or by the
facility
Inside of STAC
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List Job Description: __________________________
List 3-4 specific job tasks below and also address the
special emphasis
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Task 1.
______________________________________________
______________________________________________
______________________________________________
______________________________________________
Task 2.
______________________________________________
______________________________________________
______________________________________________
______________________________________________
Task 3.
______________________________________________
______________________________________________
______________________________________________
______________________________________________
Task 4.
______________________________________________
______________________________________________
______________________________________________
______________________________________________
Special Emphasis:
_____________________________________________
______________________________________________
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_______________________________________________________
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TASKS
Workers should list
tasks that are considered
to be high risk activities.
Some low risk tasks
may not be considered a
task:
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Get permit
Prepare tools
Set up job site
Housekeeping
Clean up area
Walk the job site
Inside of STAC
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LIST THE HAZARD(S) FOUND FOR EACH TASK
AND ADDRESS ONE LINE OF FIRE FOR EACH.
Also identify the hazards for the Special Emphasis
1A. ___________________________________________________
____________________________________________________
1B. ___________________________________________________
____________________________________________________
LOF __________________________________________________
____________________________________________________
2A. ___________________________________________________
____________________________________________________
2B. ___________________________________________________
____________________________________________________
LOF __________________________________________________
____________________________________________________
3A._________________________________________________
____________________________________________________
3B. ___________________________________________________
____________________________________________________
LOF __________________________________________________
____________________________________________________
4A_________________________________________________
____________________________________________________
4B_________________________________________________
____________________________________________________
LOF __________________________________________________
____________________________________________________
1. ____________________________________________________
____________________________________________________
2. ____________________________________________________
____________________________________________________
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HAZARDS
Worker must list hazards that
are specific to the tasks
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Examples of Specific Hazards
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Examples of Non-Specific
Hazards
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Strain to back while lifting
scaffold boards
Cuts to hands from burrs on pipe
Tripping over air hoses in area
Slips/Trips
Cuts
Strains
Worker must also list a Line of
Fire for each task identified
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Example – Pinch points to hands
while moving pipe to jack stand
Inside of STAC
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ELIMINATION &
CONTROL
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Elimination is the removal of the
hazard from the work area
Control is the reduction of the
risk associated with the hazard
(PPE, etc.)
HOW CAN THE HAZARD BE ELIMINATED?
HOW CAN THE HAZARD BE CONTROLLED?
E1A __________________________________________________
C1A __________________________________________________
E1B __________________________________________________
C1B __________________________________________________
E/LOF ________________________________________________
C/LOF ________________________________________________
E2A __________________________________________________
C2A __________________________________________________
E2B __________________________________________________
C2B __________________________________________________
E/LOF ________________________________________________
C/LOF ________________________________________________
E3A __________________________________________________
C3A __________________________________________________
E3B __________________________________________________
C3B __________________________________________________
E/LOF ________________________________________________
C/LOF ________________________________________________
E4A __________________________________________________
C4A __________________________________________________
E4B __________________________________________________
C4B __________________________________________________
E/LOF ________________________________________________
C/LOF ________________________________________________
E1 ___________________________________________________
C1 ___________________________________________________
E2 ___________________________________________________
C2 ___________________________________________________
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Worker must list an elimination
and control for every specific
hazard and line of fire identified
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Examples of Elimination –
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Use rigging to lift heavy load
File sharp edges before handling
pipe
Examples of Control –
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Minimize lifting loads/use
proper lifting techniques
Wear leather gloves when
handling pipe
STAC Scoring System
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Why have a STAC Scoring System?
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To measure strength and progress in task
analysis – Individual and Company
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To identify weak points and address with
focused training/coaching
STAC Scoring System
Outstanding – STAC card filled out completely front and back. Card listing four
specific tasks derived from your work plan, listing 8 different specific hazards, and a line
of fire hazard associated with each task. Then a control and elimination for all the
hazards that worker has identified. STAC very thorough and well thought out.
Acceptable – Front of card looks good, tasks are listed. Hazards were identified for
each task. The controls and eliminations are reasonable for the hazards .
Unacceptable - Not filling out a STAC before beginning work, performing task not
identified on STAC, date changed, front incomplete or inaccurate information, no special
emphasis, no signature of foreman/crew leader, vague task or hazards, no controls or
eliminations for hazards identified, less than three task and six hazards associated with
those tasks.
Outstanding STAC
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Safety Task Analysis Card (STAC)
I commit to follow the rules, policies and procedures
under all circumstances and will not take any shortcuts
for any reason.
Today's Date:_3/15/13_______ Start Time:__7:00 AM____
My Name: ____John Smith___________________________
My Company Name: ___The Pipe Company___________________
My Foreman/Crew Leader/Coach:_ Joe Safety___________
My Job Location: ___A-1800____________________________
I listed all co-workers in my crew and before
beginning work I will discuss hazards, eliminations
and controls so we do not get injured or cause any
incidents.
___T. Newton , B. Alexander, J. Finley____________________
___________________________________________________
At Risk Employee Only Information: Yes or No
I started the At-Risk program on: Date ________________
I have completed the At-Risk test: Date________________
Job Site Emergency Plan:
1. What Chemicals am I working around:
(List) ___Chlorine, Hydrogen, and Caustic_______________
_____________________________________________________
2. What is the wind direction: (check often)
7am/pm ___S________ 9:30am/pm__S____
12:30am/pm __SW_____ 2am/pm__N_______
3. Evacuation assembly point is___A-1800 Permit Building____
4. Nearest eye wash/shower station is:__#16 in SE Corner by D-101_____
5. Nearest intercom or means of communication
Location is:___Intercom west of safety shower (use a number if
available)________________
_____________________________________________________
6. Control Room or Work Authorizer’s Phone # is:
___8-5555_____________________________________________
Outstanding STAC
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Communication
What hazards from your job need to be communicated to
other workers in the area:
List: Sparks in the area from grinding and welding Maintain a safe distance_____
_when possible___________________________________________________
Personal Protective Equipment
What is the required PPE that I will need to use to protect
me from being injured:
List: Hard hat, steel toe shoes, side shields, hearing protection,
gloves, and escape respirator, Face Shield___________________________
Mobile Equipment Hazards
List all mobile equipment you have been trained for and will
be operating on this job: (Forklift, Aerial Lift, Truck, etc…)
Will be using a fork lift to remove pipe and steel off of flatbed_
truck and locate into lay down area_____________________
____________________________________________________
What are the hazards in the area that I am operating this
equipment? (pipe rack, power lines, critical equipment,
uneven surfaces, etc…)
Will have to move pipe into tight area with pumps and critical_
equipment in area, verify its on the Permit for Critical equipment_
Hand Safety
These are my potential hand hazards and this is what I will
do to mitigate these hazards: Burns to hands- Allow pipe to cool
and wear leather gloves. Crush hands- Don’t put hands between
pipe and jack stand_______________________________________
What is your reason for working safe today?
I have a wife and two children that I want to see grow up
____________________________________________________
Foreman/Crew leader/Coach reviewing and
approving STAC:
Signature: Joe Safety Date: 1/15/13___________
Outstanding STAC
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List Job Description: Install 8” galv. pipe into pipe rack List the Hazards Found for Each Task
How Can the Hazard be Eliminated?
List 3-4 specific job tasks below and also address
and Address One Line of Fire for Each
How Can the Hazard be Controlled?
the special emphasis
Also identify the hazards for the Special
Emphasis
Task 1. Unload Pipe With fork lift
1A. Caution when backing up equipment, vehicle and People E1A Use mechanical lifting device_____
Layout 8” pipe to be cut to size
1A. Muscle sprains from lifting pipe into jack stands
E1A Use mechanical lifting device_____
C1A Get help and use proper lifting techniques
1B. Loud noises in process areas from running pumps, E1B Loud noises can not be eliminated
steam blowing, and crane running
C1B Wear earplugs in affected areas
LOF Pinch points to hands and feet from moving pipe E/LOF Use tag line when moving pipe
into jack stand
C/LOF No hands between pipe and jack stand
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Task 2. Cut 8” pipe with band saw
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2A. Metal shavings in eyes from cutting pipe with saw
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2B. Wrist strain from prolong use of band saw
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LOF Cuts to hands or body while band saw in motion
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Task 3. Use 4” 7” grinder to smooth out ends and shape 3A. Cuts to body from sharp Grinder kickback
a bevel
C2 Barricade areas around grinding and cutting
C3A Wear leather gloves and long sleeves
process
E2A Cut below eye level and work up wind
C2A Wear goggles when using band saw (above)
E2B Cut in neutral position, waist high
C2B Take breaks, alternate person cutting
E/LOF Position body away from Saw impact
C/LOF No adjustments on saw unless it is unplugged
E3A Allow pipe to cool and avoid touching pipe
3B. Potential fire to paper, wood from sparks in
E3B Remove trash and wood from area
C3B Wet down floor and use fire watch
LOF Cuts/Abrasions to hands or arms from grinding wheel E/LOF Keep both hands on grinder handle
C/LOF Make sure wheel is tight and guard in place
Task 4. Rig pipe from jack stand and fly into rack
4A. Dropping load from improper rigging/defective
E4A Use rigging plan/inspect equipment
chokers
C4A Warn others and barricade area
4B. Trips/falls from extension cords/uneven areas
E4B Clean work site before making lift
Where is the Threading machine in the task?
C4B Avoid walking on uneven areas
LOF Pinch points to hands while repositioning
E/LOF Communicate with operator 100% of time
chokers or shackles
C/LOF Wear leather gloves while handling slings
Special Emphasis: Housekeeping
1. Tripping over threading machine extension cords
E1 Avoid placing cords in walk ways
2. Slipping on loose material from grinding/cutting
E2 Sweep area frequently
C1 Flag all tripping hazards/note on JEP (NOT FOR HAZARDS)
Acceptable STAC
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List Job Description: Install 8” galv. pipe into pipe rack List the Hazards Found for Each Task
List 3-4 specific job tasks below and also address
and Address One Line of Fire for Each
the special emphasis
Also identify the hazards for the Special
Emphasis
Task 1. Layout 8” pipe to be cut to size
1A. Muscle sprains from lifting pipe
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1B. Loud noises in process areas
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LOF Pinch points to hands and feet from moving pipe
into jack stand
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Task 2. Cut 8” pipe with band saw
2A. Metal shavings in eyes
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2B. Wrist strain from prolong use of band saw
LOF Cuts to hands or body while band saw in motion
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Task 3. Rig pipe from jack stand and fly into rack
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3A. Dropping load from improper rigging/defective
chokers
3B. Trips/falls from extension cords/uneven areas
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LOF Pinch points to hands while repositioning
chokers or shackles
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How Can the Hazard be Eleminated?
How Can the Hazard be Controlled?
E1A Use mechanical lifting device_
C1A Get help
E1B Loud noises can not be eliminated
C1B Wear earplugs
E/LOF Use tag line
C/LOF No hands between pipe and jack stand
E2A Work up wind
C2A Wear goggles
E2B Cut in neutral position
C2B Take breaks
E/LOF Position body away from impact
C/LOF No adjustments on saw unless it is unplugged
E3A Inspect equipment
C3A Barricade area
E3B Clean work site before making lift
C3B Avoid walking on uneven areas
E/LOF Communicate with operator 100% of time
C/LOF Wear leather gloves
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Special Emphasis: Housekeeping
1. Tripping over threading machine extension cords
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2. Slipping on loose material from grinding/cutting
E1 Avoid placing cords in walk ways
C1 Flag all tripping hazards/note on JEP
E2 Sweep area frequently
C2 Barricade areas around grinding and cutting
Unacceptable STAC
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List Job Description: Install 8” galv. pipe into pipe rack List the Hazards Found for Each Task
List 3-4 specific job tasks below and also address
and Address One Line of Fire for Each
the special emphasis
Also identify the hazards for the Special
Emphasis
Task 1. Layout pipe
1A. Muscle sprains
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1B. Loud noises
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LOF Pinch points
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Task 2. Cut pipe
2A. Metal shavings in eyes
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2B. Wrist strain
LOF Cuts
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Task 3. Rig pipe
3A. Dropping load
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3B. Trips/falls
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LOF Pinch points
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How Can the Hazard be Eleminated?
How Can the Hazard be Controlled?
E1A Use lifting device_
C1A Get help
E1B Can not be eliminated
C1B Wear earplugs
E/LOF Use tag line
C/LOF No hands between pipe and jack stand
E2A Work up wind
C2A Wear goggles
E2B Better position
C2B Take breaks
E/LOF Better position
C/LOF No adjustments on saw unless it is unplugged
E3A Inspect equipment
C3A Barricade area
E3B Housekeeping
C3B Walk carefully
E/LOF Communicate
C/LOF Wear gloves
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Special Emphasis: Housekeeping
1. Tripping over threading machine extension cords
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2. Slipping on loose material from grinding/cutting
E1 Avoid placing cords in walk ways
C1 Flag all tripping hazards/note on JEP
E2 Sweep area frequently
C2 Barricade areas around grinding and cutting
Practice Time
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Please take this time to practice filling out a
quality STAC card.
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Each person should fill out a STAC card for a
job that he/she might perform in the field.