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Welding and fabrication · Canada

FLHA for steel fabrication

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 steel fabrication 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, being hit by heavy equipment, fire from hot works and saw cuts and kickback.

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FLHA example: steel fabrication

This is a complete FLHA for steel fabrication, 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)
Workshop steel fabrication · Welding and fabrication · Example
Document FLHA-001 · Rev 1

Job steps, hazards and controls

#Job stepHazardsRisk beforeControlsRisk after
1Move steel with a forklift or overhead crane, keeping walkways clear
  • Being hit by heavy equipment
  • Crane and lifting failure
Critical
  • Separate people and equipment with barriers, exclusion zones and marked walkways. Engineering (guarding)
  • Use equipment with working backup alarms, cameras and lights. Engineering
  • Have a site traffic plan showing equipment routes, loading areas and pedestrian paths. Administrative
  • Use a spotter when backing up or working near people. Administrative
  • Make eye contact with the operator before going near. Stay out of the swing radius. Administrative
  • Operators are trained and competent for each machine. Administrative
  • Do a pre-start check on each machine every day and record it. Administrative
  • Wear hi-vis clothing and a hard hat. PPE
  • Barricade the lift zone and keep everyone out from under the load. Engineering (guarding)
  • Use a crane rated for the load at the radius, set up on firm ground with outrigger pads. Engineering
  • Check slings, chains, shackles and hooks before use. Remove anything damaged or not tagged. Engineering
  • Plan the lift: weight, radius, ground, path and landing area. Use a written lift plan for complex lifts. Administrative
  • Use certified crane operators and trained riggers and signallers, as your province requires. Administrative
  • Use tag lines to control loads and agree on clear radio or hand signals. Administrative
  • Stop lifting in high wind or when the operator cannot see the signaller. Administrative
  • Never ride on a load or hook. Administrative
  • Wear a hard hat, hi-vis, gloves and safety boots. PPE
Medium
2Cut and drill steel with guards in place
  • Saw cuts and kickback
  • Angle grinder injuries
  • Loud noise
High
  • Keep blade guards fitted and working, and use the riving knife on table saws. Engineering
  • Use push sticks and clamps, and support long pieces so they do not pinch the blade. Engineering
  • Use a sharp, undamaged blade made for the material. Administrative
  • Stand to one side of the blade line, out of the kickback path. Administrative
  • Let the blade stop fully before reaching in or putting the saw down. Administrative
  • 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
Medium
3Weld in a booth with extraction
  • Welding and cutting fumes
  • Eye injuries
  • Fire from hot works
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
  • 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
  • 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
Medium
4Handle hot and sharp parts with gloves
  • Burns from hot surfaces
  • Cuts from sharp edges
Medium
  • 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
  • Deburr or cover sharp edges, and fit edge protectors on exposed sheet metal. Engineering
  • Use knives with retractable or self-retracting blades. Engineering
  • Cut away from your body and keep your other hand clear. Administrative
  • Put used blades in a blade bin or sharps container. Administrative
  • Use two people to handle large sheets of metal or glass. Administrative
  • Wear cut-resistant gloves and long sleeves. PPE
Low
5Store gas bottles upright and chained
  • Flammable liquids and gases
  • Compressed air
High
  • 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
  • Fit whip checks (safety cables) on hose joints and check hoses before use. Engineering
  • Fit a pressure regulator and keep pressure to the tool's rating. Engineering
  • Turn off and bleed the line before disconnecting. Administrative
  • Never use compressed air to clean clothes or skin, or point it at anyone. Administrative
  • Wear safety glasses and hearing protection. PPE
Medium
6Sweep up slag and offcuts
  • Poor housekeeping and waste
Medium
  • Order materials to size and send packaging back where you can. Elimination
  • Put waste bins and chutes close to the work. Engineering
  • Clean as you go, and do a full clean up at the end of each day. Administrative
  • Keep exits, stairs and walkways clear at all times. Administrative
  • Stack materials neatly on level ground, away from edges. Administrative
  • Wear gloves when handling waste. PPE
Low

PPE

Welding helmet (CSA Z94.3)Welding glovesCSA green triangle safety boots (CSA Z195)Safety glasses (CSA Z94.3)Hearing protectionCoverallsHigh-visibility vest (CSA Z96)Hard hat (CSA Z94.1)Work glovesN95 respiratorFace shieldCut-resistant glovesRespirator fit tested to CSA Z94.4 (P100 for dust, or the type the air test calls for)Safety goggles

Plant and equipment

Welding machineAngle grinderOxy-acetylene torchLift truck (forklift): Provincial lift truck operator trainingMobile crane: Provincial crane operator certification, qualified rigger

Permits and plans

Lift planHot 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 steel fabrication

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 steel fabrication

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

The safe sequence of work

  1. Move steel with a forklift or overhead crane, keeping walkways clear
  2. Cut and drill steel with guards in place
  3. Weld in a booth with extraction
  4. Handle hot and sharp parts with gloves
  5. Store gas bottles upright and chained
  6. Sweep up slag and offcuts

Hazards to watch on steel fabrication

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

Step 5Compressed airAn air hose whips when a fitting fails, or air blown at skin or eyes drives dirt in and causes injury.
Step 3Welding 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 5Flammable liquids and gasesGasoline, solvents, thinners and propane catch fire or explode when vapour reaches a spark, flame or hot surface.
Step 1Crane and lifting failureA load falls or swings, or the crane tips, crushing workers under or near the lift.
Step 2Angle grinder injuriesThe disc shatters, binds or kicks back, causing deep cuts to legs and hands or eye injuries.
Almost certainLikelyPossibleUnlikelyRareHow bad it could be: First aid only to FatalityBA
Highest risk on steel fabrication: 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?

Licences and legal requirements in Canada

Equipment on this job that needs a licence, ticket or training:

  • Lift truck (forklift): Provincial lift truck operator training
  • Mobile crane: Provincial crane operator certification, qualified rigger

Employers must identify hazards before work starts and control them, and workers must be told about them. A field level hazard assessment is done on site, at the start of each shift or task, and reviewed again when conditions change.

Rules that apply: Provincial OHS regulation, cranes and hoisting.

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 steel fabrication

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 steel fabrication?

Provincial OHS law requires hazards to be assessed and controlled before work starts. A field level hazard assessment (FLHA) for steel fabrication 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 steel fabrication?

Usually Welding helmet (CSA Z94.3), Welding gloves, CSA green triangle safety boots (CSA Z195), Safety glasses (CSA Z94.3), Hearing protection, Coveralls, High-visibility vest (CSA Z96), Hard hat (CSA Z94.1), Work gloves, N95 respirator, Face shield, Cut-resistant gloves, Respirator fit tested to CSA Z94.4 (P100 for dust, or the type the air test calls for), Safety goggles. The site rules may add more, so check with the general contractor.

More welding and fabrication FLHAs

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

Sources