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Welding and fabrication · United States

JHA for welding

By Safety PaperworkBuilt from OSHA standards and guidance · How we write and check theseUpdated

OSHA expects employers to find and control hazards on every job, and many general contractors require a written JHA for welding before you start.

A JHA breaks the job into steps, lists the hazards in each step and the controls that protect the crew, and the crew signs it. 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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JHA example: welding

This is a complete JHA 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.

Job Hazard Analysis (JHA)
On-site welding · Welding and fabrication · Example
Document JHA-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 35 feet 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 unauthorized entry". Administrative
  • Make the site safe at the end of each day: cover holes, lower plant, remove ladders and lock tools away. Administrative
  • Use a spotter when moving plant 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 GFCIs on all 120-volt, 15, 20 and 30 amp temporary receptacles, or a written assured equipment grounding conductor program run by a competent person with recorded tests (29 CFR 1926.404(b)(1)). 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 cords 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, galvanizing 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 plant 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 at arm's length, 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 35 feet 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 (NFPA 51B), longer if the permit says so. Administrative
  • Check for smoldering 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 (ANSI Z87.1)Welding glovesSafety-toe boots (ASTM F2413)CoverallsHalf-face respirator (P100 cartridges)Hearing protection (earmuffs or plugs)Face shield (ANSI Z87.1)Safety glasses (ANSI Z87.1)Safety goggles (ANSI Z87.1)High-visibility safety apparel, ANSI/ISEA 107 Class 2 or 3 (Type R near roadways)Work glovesCut-resistant gloves

Plant and equipment

Welding machineAngle grinderPortable generator

Permits and plans

Hot work permit (fire watch at least 60 minutes after, NFPA 51B)

Emergency

Call 911. Add the nearest hospital, the assembly point and the first aid / cpr person for your site.

Sign-off

Supervisor and every worker sign to confirm they have read and understood this JHA.

Free JHA 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 JHA

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, asphalt, solder or freshly welded metal burns the skin.
Step 1Flammable liquids and gasesGasoline, solvents, thinners and propane catch fire or explode when vapor 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 United States 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):

  • Will anyone work 6 feet or more above a lower level?
  • Will anyone use a ladder or stepladder?
  • Will anyone work on a roof?
  • Is there a skylight, fiberglass panel or other fragile roofing?
  • Will you use a scaffold or rolling tower?

Why JHAs get rejected

General contractors send documents back for these reasons. This example avoids them, but check yours too.

  • Generic steps such as "work safely" or "use PPE" with no task-specific hazards or controls.
  • No OSHA standards referenced for the hazards that have them, such as fall protection, ladders, scaffolds or silica.
  • No competent person named for fall protection, excavation, scaffolds or silica where those hazards exist.
  • Equipment listed without inspection requirements, and no training listed for the people using it.
  • Respirators listed with no respiratory protection program, medical clearance or fit test.
  • Controls rely only on PPE when engineering controls such as guardrails, wet cutting or extraction are feasible.
  • No crew sign-off, or no date and revision when the job has changed.

Questions

Do I need a JHA for welding?

OSHA expects employers to find and control hazards on every job, and many general contractors require a written JHA for welding before you start.

Who signs the JHA?

The supervisor or competent person who prepared it signs, and every crew member signs to show they were trained on the hazards and controls before the job starts. Many general contractors also sign to accept it.

How long do I keep it?

Keep this JHA on site during the job, and keep it with the training and inspection records for at least 1 year after the job (longer if your state plan or general contractor requires it). OSHA does not set a retention period for JHAs themselves.

What PPE is needed for welding?

Usually Welding helmet (ANSI Z87.1), Welding gloves, Safety-toe boots (ASTM F2413), Coveralls, Half-face respirator (P100 cartridges), Hearing protection (earmuffs or plugs), Face shield (ANSI Z87.1), Safety glasses (ANSI Z87.1), Safety goggles (ANSI Z87.1), High-visibility safety apparel, ANSI/ISEA 107 Class 2 or 3 (Type R near roadways), Work gloves, Cut-resistant gloves. The site rules may add more, so check with the general contractor.

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

Sources