The number zero is significant to tradespeople. It’s what we in the mechanical, electrical and plumbing industry all strive for: zero team members spending nights in the hospital, zero days away from our families because of an injury, zero incidents that take us away from what we enjoy doing in our free time and zero general liability claims.

Over the last couple of decades, we have witnessed several near misses: close calls linked to blowouts and unexpected water releases during pressure testing. Pressure testing is essential for verifying the integrity of piping systems, vessels and components. However, it is one of the most hazardous phases in plumbing and piping work. 

A new approach to pressure-testing safety

As MEP professionals, we take potentially life-threatening situations very seriously. They serve as a wake-up call for practitioners. Blowouts and releases during testing operations highlight critical vulnerabilities in pressure-testing practices and protocols — and evidence knowledge or practice gaps among trades workers. That is why it was important to develop a new approach to tackle them — not only for my company, but to make our industry safer overall.

Step 1: Identifying the training gap

To uncover the root causes of dangerous blowouts during pressure-testing activities, we brought together our Environmental, Health and Safety team, field leaders, engineers and manufacturers, and embarked on a thorough industry-wide research study, formed an internal Job Hazard Analysis task force and explored past known incidents. 

That search led us directly to press fittings and soon revealed a startling truth: the industry had endured a 20-year deficit in training for press fittings, resulting in inconsistent methods and elevated risk during system testing.

We identified a trend where teams would sometimes pressurize a system to full test pressure for both pneumatic and hydrostatic tests, without first completing a low-pressure leak check or accounting for press fittings’ behavior under high pressures. In addition, pneumatic testing carries significantly more risk. 

The low-pressure leak check is critical because it will identify unpressed or faulty joints. If the system is charged to higher pressures without the low-pressure check, unpressed joints can sometimes hold, leading the team to believe the system is intact. 

Because of inconsistent training and a lack of knowledge in the industry, many practitioners simply weren’t aware that press-connected pipes must be tested differently than traditional joining methods. Furthermore, communication challenges between testing and install teams created gaps in safety controls.

Why press fittings require extra caution

Press fittings, mechanical pipe connectors using O-rings and a crimped sleeve instead of traditional joining methods, can be dangerous if not installed properly. Unlike traditional joining methods, press fittings rely on an elastomer seal (such as an EPDM O-ring) and a pressed collar to hold the pipe in place. If a fitting is not fully pressed or the pipe isn’t inserted to the proper depth, the connection will not withstand high pressure.

We confirmed the suspected training inconsistency by interviewing hundreds of pipefitters and plumbers who had worked with a variety of companies throughout the country and had varied educational backgrounds, to gauge their level of awareness of the special requirements for testing press-fit connections. 

The results were the same: Regardless of where they had worked or learned the trade, very few were trained in proper handling of press fittings.

Getting back to zero

It was identified that if we wanted to achieve zero close calls while testing, we needed a new outlook and methodology that bridged the significant knowledge gap and the safety controls used by trade professionals nationwide. 

Safety isn’t only about compliance; it’s about culture, innovation and collaboration. That’s why we started by overhauling our company’s approach to pressure testing, focusing on the following areas: safety policy, JHA design, hands-on training and common language for our pressure-testing safety controls and tools. 

Step 2: Building a safer policy framework

Driven by a commitment to robust quality assurance and quality control, we started with accepted pressure-testing policies and procedures. The safe setup and operation of pressure-testing equipment were key.

We quickly launched our QA/QC training to ensure proper implementation. The program gained momentum and achieved full systemwide adoption. The results of the new pressure-testing policies and procedures spoke volumes. We noted improved testing efficiency, enhanced system accuracy and significant reductions in risk — saving both time and money.

Pro tip: We also revamped our pre-task safety plans and JHA for pressure-testing reports to ensure accurate, thorough documentation and better safety controls throughout the testing process. It’s great to review your communication plans as well, so you can communicate hazards to all personnel and keep relief valves and isolation points accessible at all times.

Step 3: Company job training and beyond 

We value continuous aggressive improvement. So, to encourage adoption and understanding of the policies, we updated our internal courses to reflect our findings. However, we didn’t stop with our internal training. 

Department of Labor apprenticeships are recognized nationwide and have specific on-the-job training requirements that must be met for an apprentice to become a journeyman. During the course of our research, we realized these requirements no longer accurately reflected the work in each trade. The requirements, at times, focused on antiquated pipefitting tasks that some apprentices no longer perform. 

So, we collaborated with a notable trade education program and several other experts in the field to rewrite the DOL OJT requirements for sheet metal, plumbing and piping trades, making sure to implement our findings and bridge the education gap in pressure testing and a number of other areas. 

Our updates were adopted by the DOL in 2021 and helped make the industry safer overall. Currently, these changes also influence Associated Builders and Contractors’ national OJT requirements, impacting apprenticeship training across the United States.

Part of the training gap also led team members not to follow the manufacturer’s specifications because many were unaware of, or misunderstood, the instructions. In addition to helping revise governmental training procedures, we worked directly with manufacturers to clarify the specifications for our teams.

Pro tip: We worked with the manufacturer, as a testing partner, to ensure that manufacturers had up-to-date information regarding the field use of equipment. 

Step 4: Safety made simple — easy access to tools

Finally, we needed to make it simpler and easier for our teams to follow our updated policies. Sound procedures and training are critical. However, the best way to ensure compliance with procedures and policies is to make following them as easy as possible. 

Pro tip: We learned throughout the process that the simpler you make it for teams to follow policies, the better the results. Having all the necessary tools grouped contributes to safer, more sustainable work environments.

Recognizing that policies and training alone weren’t enough, we introduced pressure-testing toolkits that were easy to understand and use. These kits consolidated essential equipment in one location and created a common color-coding language. From air compressors to gauges, items were packaged in compact, easy-to-use units. When we provide everything our employees need in one compact place, they are less inclined to deviate from policies or take shortcuts. 

The kits for pressure testing also ensure quality control for equipment, meaning that all hoses and fittings are rated above the maximum test pressure and that gauges are appropriately inspected and calibrated before use. The kits also ensure that OSHA-compliant personal protective equipment, including eye protection, gloves, face shields and warning tape to restrict access to the testing area, is easily accessible. 

Implementing this new blueprint helped us uncover valuable insights that benefit the entire industry. What’s the payoff? We have had zero pressure-testing safety incidents since the program’s inception. Because of this focus on safety, simplicity, consistency and updating education, we are able to virtually eliminate near misses related to pressure testing. In addition, we boosted team morale, safety, and engagement by demonstrating to our teams that controlling risk was of the utmost importance. 

Doug Edrington currently serves as construction manager for TDIndustries, leveraging his expertise to support large-scale projects, including data centers, manufacturing facilities and military bases. He was named Safety Champion of the Year in 2024 by Associated General Contractors of America and is an undeniable leader and innovator in the mechanical, electrical and plumbing field.