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Welding and fabrication · Canada

FLHA for welding

By Safety PaperworkBuilt from provincial OHS law and CCOHS guidance · How we write and check theseUpdated

Provincial OHS law requires hazards to be assessed and controlled before work starts. A field level hazard assessment (FLHA) for welding is done on site at the start of the shift and again whenever conditions change.

It lists the tasks, hazards and controls, and every worker signs on before starting and signs off at the end of the shift. The main hazards are welding and cutting fumes, fire from hot works, public entering the work area and electric shock from cords and power tools.

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FLHA example: welding

This is a complete FLHA for welding, with 6 job steps. Open it in the builder to add your site, crew and signatures, change anything, and download a PDF. Or download the free Word template below and fill it in by hand.

Field Level Hazard Assessment (FLHA)
On-site welding · Welding and fabrication · Example
Document FLHA-001 · Rev 1

Job steps, hazards and controls

#Job stepHazardsRisk beforeControlsRisk after
1Get a hot work permit and clear flammables from the area
  • Fire from hot works
  • Flammable liquids and gases
Critical
  • Use cold work methods where you can, such as bolting, press fittings or cutting with a saw instead of a torch. Elimination
  • Move anything that can burn at least 10 metres away, or cover it with fire blankets. Engineering (guarding)
  • Fire from hot works: see step 6 for the full controls Administrative
  • Use non-flammable or water-based products where you can. Substitution
  • Keep ignition sources away: no smoking, no hot work and no running engines near flammables. Engineering (guarding)
  • Store fuels and solvents in approved, closed containers in a ventilated area away from the work. Engineering
  • Refuel equipment outdoors with the engine off and cool. Administrative
  • Keep only what you need for the day on site. Administrative
  • Store gas cylinders upright, secured and outdoors. Administrative
  • Keep a suitable fire extinguisher where flammables are used or stored. Administrative
  • Wear chemical gloves and safety glasses when pouring or mixing. PPE
Medium
2Set up welding screens to protect others from arc flash
  • Eye injuries
  • Public entering the work area
High
  • Use tool guards and screens to stop flying particles. Engineering
  • Use dust extraction and water to keep dust out of the air. Engineering
  • Keep others out of the area when cutting, grinding or chipping. Administrative
  • Keep an eye wash station or eye wash bottles on site. Administrative
  • Wear safety glasses at all times, goggles for dust and chemicals, and a face shield for grinding. PPE
  • Fence off the site with secure temporary fencing and lock the gates when you leave. Engineering (guarding)
  • Give pedestrians a safe, marked path around the work, with ramps for strollers and wheelchairs. Engineering (guarding)
  • Use hoarding, covered walkways or catch fans where work is above public areas. Engineering
  • Put signs at each entry: site name, contact number and "No unauthorised entry". Administrative
  • Make the site safe at the end of each day: cover holes, lower buckets and booms, remove ladders and lock tools away. Administrative
  • Use a spotter when moving equipment or materials across public paths. Administrative
Low
3Check leads and earth clamp, keeping leads dry
  • Electric shock from cords and power tools
  • Slips and trips
High
  • Use battery-powered tools where you can. Substitution
  • Use GFCI protection on all temporary power and portable tools. Engineering
  • Keep cords off the ground and out of water, using stands or hooks. Engineering
  • Check cords, plugs and tools before every use. Tag out and remove anything damaged. Administrative
  • Do not use tools in rain or wet areas unless they are rated for it. Administrative
  • Wear safety boots and dry gloves. PPE
  • Plan walkways and keep them clear of materials, hoses and leads. Elimination
  • Run leads and hoses overhead on hooks or stands, or along walls, not across walkways. Engineering
  • Fill or cover holes, and lay boards or mats on muddy access paths. Engineering
  • Clean up offcuts, packaging and spills as you go, not at the end of the day. Administrative
  • Keep work areas, stairs and access paths well lit. Administrative
  • Wear safety boots with good grip, laced up. PPE
Low
4Weld with fume extraction or a respirator, especially on galvanised steel
  • Welding and cutting fumes
  • Burns from hot surfaces
Critical
  • Remove paint, galvanising and coatings from the weld area first, or use a process that makes less fume. Substitution
  • Use fume extraction (local exhaust ventilation) close to the weld. Engineering
  • Weld outdoors or in a well-ventilated area, and keep your head out of the fume plume. Engineering
  • Never weld or cut in a confined space without testing the air and using forced ventilation. Administrative
  • Wear a powered air respirator or fitted respirator when extraction is not enough. PPE
  • Wear a welding helmet, welding gloves and flame-resistant clothing. PPE
  • Isolate heating systems and let parts cool before you touch them. Elimination
  • Fit guards or insulation on hot pipes and equipment. Engineering
  • Mark hot items with chalk or a "HOT" sign so others know. Administrative
  • Keep a first aid kit and cool running water nearby for burns. Administrative
  • Wear heat-resistant gloves and long sleeves. PPE
Medium
5Grind welds with guards on
  • Angle grinder injuries
  • Loud noise
  • Eye injuries
High
  • Use a guarded saw or a different tool where you can. Substitution
  • Keep the guard on and use the side handle. Never remove the guard. Engineering
  • Use the right disc for the job, rated for the grinder's speed. Check it for cracks first. Administrative
  • Only trained people change discs, with the grinder unplugged or the battery out. Administrative
  • Keep both hands on the grinder and let the disc stop before putting it down. Administrative
  • Use quieter tools and methods, such as cut-to-size materials, low-noise machines and battery tools. Substitution
  • Keep noisy equipment away from work areas, and use screens or distance between the noise and people. Engineering (guarding)
  • Keep tools maintained and use mufflers on compressors and generators. Engineering
  • Limit time on noisy tools and rotate workers. Administrative
  • If you have to shout to be heard 1 metre away, wear hearing protection. Administrative
  • Eye injuries: see step 2 for the full controls Administrative
Medium
6Fire watch after finishing, then sign off the permit
  • Fire from hot works
  • Fire and emergencies
Critical
  • Use cold work methods where you can, such as bolting, press fittings or cutting with a saw instead of a torch. Elimination
  • Move anything that can burn at least 10 metres away, or cover it with fire blankets. Engineering (guarding)
  • Use fire-resistant screens to stop sparks reaching people or gaps in walls and floors. Engineering
  • Get a hot work permit before starting. Administrative
  • Keep a charged fire extinguisher and fire blanket at the work spot. Administrative
  • Keep a fire watch during the work and for at least 60 minutes after you finish. Administrative
  • Check for smouldering behind walls, in ceilings and under floors before you leave. Administrative
  • Wear flame-resistant clothing, welding gloves and eye or face protection. PPE
  • Provide fire extinguishers suited to the site, checked and easy to reach. Engineering
  • Keep exits and escape routes clear and signed. Engineering
  • Have a site emergency plan: alarm, exits, assembly point and emergency contacts. Administrative
  • Keep a stocked first aid kit and at least one trained first aider on site. Administrative
  • Know the site address and how emergency services get in. Call 911. Administrative
  • Go through the emergency plan with every worker and visitor at induction. Administrative
  • Keep flammable materials and rubbish away from exits and escape routes. Administrative
Medium

PPE

Welding helmet (CSA Z94.3)Welding glovesCSA green triangle safety boots (CSA Z195)CoverallsRespirator fit tested to CSA Z94.4 (P100 for dust, or the type the air test calls for)Hearing protectionFace shieldSafety glasses (CSA Z94.3)Safety gogglesHigh-visibility vest (CSA Z96)Work glovesCut-resistant gloves

Plant and equipment

Welding machineAngle grinderPortable generator

Permits and plans

Hot work permit

Emergency

Call 911. Add the nearest hospital, the muster point and the first aid attendant for your site.

Sign-off

Supervisor and every worker sign to confirm they have read and understood this FLHA, then sign off at the end of the shift.

Free FLHA template for welding

Word (.docx) and PDF, Letter landscape, no email needed. Fill in your site details, then print or send it.

Word template (.docx)PDF template

Make yours in 2 minutes

Same document, filled in for your job. Answer a few yes or no questions, the crew signs on the phone, and you send the PDF.

Start this FLHA

Pre-start checklist for welding

Tick these off before work starts. They come from the hazards, permits and equipment in this job.

The safe sequence of work

  1. Get a hot work permit and clear flammables from the area
  2. Set up welding screens to protect others from arc flash
  3. Check leads and earth clamp, keeping leads dry
  4. Weld with fume extraction or a respirator, especially on galvanised steel
  5. Grind welds with guards on
  6. Fire watch after finishing, then sign off the permit

Hazards to watch on welding

The hazards most specific to this job, and the step where each one comes up.

Step 4Welding and cutting fumesWelding, cutting and brazing give off metal fumes and gases that damage the lungs and can cause cancer.
Step 4Burns from hot surfacesTouching hot pipes, tools, bitumen, solder or freshly welded metal burns the skin.
Step 1Flammable liquids and gasesGasoline, solvents, thinners and propane catch fire or explode when vapour reaches a spark, flame or hot surface.
Step 5Angle grinder injuriesThe disc shatters, binds or kicks back, causing deep cuts to legs and hands or eye injuries.
Step 6Fire and emergenciesA fire, injury or other emergency happens and workers cannot get out, raise the alarm or get first aid in time.
Step 3Electric shock from cords and power toolsDamaged cords, plugs or tools, or water near power, give the user an electric shock.
Almost certainLikelyPossibleUnlikelyRareHow bad it could be: First aid only to FatalityBA
Highest risk on welding: Critical before controls (B), down to Medium after controls (A), on the Canada 5 by 5 risk matrix (likely and serious injury becomes unlikely and serious injury).

What changes on your site

This example covers the job itself. Your site may add more. Add controls for any of these that apply (the builder asks you these as yes or no questions):

  • Could anyone fall 3 metres or more, or fall any distance into machinery, water, a hazardous substance or through an opening?
  • Will anyone use a ladder or stepladder?
  • Will anyone work on a roof?
  • Is there a fragile roof, skylight or clear roof sheet?
  • Will you use a scaffold or mobile tower?

Why FLHAs get rejected

Prime contractors and COR auditors send documents back for these reasons. This example avoids them, but check yours too.

  • End of shift boxes already say "None" when the form was signed at the start of the shift.
  • One FLHA reused for days or weeks, or a "review by" date a month away, when the work and conditions change daily.
  • No time of assessment and no record of any revision, which Alberta s.7(3) requires.
  • Workers signed that they "read" it, but nothing shows they took part, which Alberta s.8(1) requires.
  • Work at height with no fall protection plan where the province requires one, or no written rescue procedure for workers using fall arrest.
  • Permits or locates required on site but no permit or ticket numbers recorded.
  • No re-assessment entry after an obvious change such as weather, a new task or a new crew member.

Rules by province for welding

Province or territoryKey local ruleRegulator
OntarioFall protection (O. Reg. 213/91 s.26) applies at a fall of more than 3 m, more than 1.2 m where the work area is used as a path for a wheelbarrow or similar equipment, and at any height into operating machinery, water or other liquid, a hazardous substance, or through an opening.Ontario Ministry of Labour, Immigration, Training and Skills Development
British ColumbiaFall protection is required where a fall of 3 m or more may occur (s.11.2). A written fall protection plan is required at 7.5 m or more where there are no permanent guardrails (s.11.3).WorkSafeBC
AlbertaA hazard assessment must be done before work begins, and before a new work site is built (OHS Code s.7(1)). The results must be written down with the controls (s.7(2)).Alberta Occupational Health and Safety
QuebecGuardrails (Safety Code s.2.9.1, as amended by Decret 63-2025) are needed where a worker could fall into liquid or a hazardous substance, onto moving parts or dangerous equipment, 1.2 m or more when using a vehicle, 1.5 m or more when handling a load, and more than 3 m in all other cases.CNESST (Commission des normes, de l'equite, de la sante et de la securite du travail)
ManitobaA prime contractor is required whenever more than one employer or self employed person works on the site at the same time (Act s.7).Manitoba Workplace Safety and Health Branch
SaskatchewanAn occupational health committee is required at 10 or more workers of one employer (Act s.3-22).Saskatchewan Ministry of Labour Relations and Workplace Safety, OHS Division
Nova ScotiaWorkers must be trained in fall protection before using it or working in, supervising or planning work in a fall protection area, with a refresher at least every 3 years (WHSR s.21.19).Nova Scotia Department of Labour, Skills and Immigration, Safety Branch (OHS)
New BrunswickFall protection is needed from 3 m above water or the nearest permanent safe level (Reg 91-191 s.49(1)(a)(i)).WorkSafeNB
Newfoundland and LabradorGive written notice to the minister before starting a construction project that will last 30 days or more, with the site, location, type of work and number of workers (Regs s.8).Government Services, Occupational Health and Safety Division
Prince Edward IslandFall protection is needed from 3 m above the nearest safe surface or water (Fall Protection Regulations s.2(1)(a)).Workers Compensation Board of PEI, OHS Division
YukonEvery employer must do hazard assessments with the committee, representative or workers, and redo them after significant changes or incidents (Regs s.1.03.01).Yukon Workers' Safety and Compensation Board
Northwest TerritoriesFall protection is needed from 3 m, or lower if there is a risk of injury (s.119(1)). Guardrails are needed for falls of 1.2 m to 3 m at permanent work sites (s.119(2)).Workers' Safety and Compensation Commission (WSCC)
NunavutNo 911. To reach the RCMP in an emergency, dial your community's first three digits then 1111 (Iqaluit: 979-1111). Put the local fire, ambulance and RCMP numbers on every FLHA.Workers' Safety and Compensation Commission (WSCC)

Questions

Do I need an FLHA for welding?

Provincial OHS law requires hazards to be assessed and controlled before work starts. A field level hazard assessment (FLHA) for welding is done on site at the start of the shift and again whenever conditions change.

Who signs the FLHA?

The supervisor and every worker take part in the assessment and sign on before work starts, then sign off at the end of the shift. Review it and re-sign whenever the task or conditions change.

How long do I keep it?

Keep completed hazard assessments for at least 3 years (COR auditors sample the last 12 months). Review this FLHA and re-sign whenever the task, crew or conditions change.

What PPE is needed for welding?

Usually Welding helmet (CSA Z94.3), Welding gloves, CSA green triangle safety boots (CSA Z195), Coveralls, Respirator fit tested to CSA Z94.4 (P100 for dust, or the type the air test calls for), Hearing protection, Face shield, Safety glasses (CSA Z94.3), Safety goggles, High-visibility vest (CSA Z96), Work gloves, Cut-resistant gloves. The site rules may add more, so check with the general contractor.

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Blank FLHA template: free FLHA templates. Also for other countries: Australia (SWMS) · United Kingdom (RAMS) · United States (JHA)

Sources