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Welding and fabrication · United States

JHA for steel fabrication

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

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JHA example: steel fabrication

This is a complete JHA 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.

Job Hazard Analysis (JHA)
Workshop steel fabrication · Welding and fabrication · Example
Document JHA-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 authorized for each machine. Forklift and telehandler operators are trained, evaluated and certified by the employer (29 CFR 1910.178(l), via 1926.602(d)). 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 a certified crane operator who has also been evaluated by the employer, with the evaluation documented on site (29 CFR 1926.1427), plus a qualified rigger (1926.1425) and a qualified signal person (1926.1428). 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 signal person. 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 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
Medium
3Weld in a booth with extraction
  • Welding and cutting fumes
  • Eye injuries
  • Fire from hot works
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
  • 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 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
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 point air at anyone or use it on clothes or skin. Air for cleaning must be under 30 psi with chip guarding (29 CFR 1926.302(b)(4)). 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 dumpsters and waste 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 (ANSI Z87.1)Welding glovesSafety-toe boots (ASTM F2413)Safety glasses (ANSI Z87.1)Hearing protection (earmuffs or plugs)CoverallsHigh-visibility safety apparel, ANSI/ISEA 107 Class 2 or 3 (Type R near roadways)Hard hat (ANSI Z89.1)Work glovesN95 respiratorFace shield (ANSI Z87.1)Cut-resistant glovesHalf-face respirator (P100 cartridges)Safety goggles (ANSI Z87.1)

Plant and equipment

Welding machineAngle grinderOxy-acetylene torchForklift: Trained and evaluated operator, certified by the employer with name, training date, evaluation date and evaluator; re-evaluated every 3 years (29 CFR 1910.178(l), via 1926.602(d))Mobile crane: Operator certified by an accredited body or audited employer program (29 CFR 1926.1427) and evaluated by the employer, with a signed evaluation on site (1926.1427(f)); qualified rigger (1926.1425) and qualified signal person (1926.1428)

Permits and plans

Critical lift planHot 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 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 JHA

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, asphalt, solder or freshly welded metal burns the skin.
Step 5Flammable liquids and gasesGasoline, solvents, thinners and propane catch fire or explode when vapor 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 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?

Licences and legal requirements in United States

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

  • Forklift: Trained and evaluated operator, certified by the employer with name, training date, evaluation date and evaluator; re-evaluated every 3 years (29 CFR 1910.178(l), via 1926.602(d))
  • Mobile crane: Operator certified by an accredited body or audited employer program (29 CFR 1926.1427) and evaluated by the employer, with a signed evaluation on site (1926.1427(f)); qualified rigger (1926.1425) and qualified signal person (1926.1428)

OSHA requires employers to find and fix hazards and to train workers on them. A JHA breaks the job into steps, lists the hazards in each step and the controls that protect the crew. General contractors often require one before you start.

Rules that apply: 29 CFR 1926 Subpart O; 29 CFR 1926 Subpart CC; 29 CFR 1926 Subpart I; 29 CFR 1926.52; 29 CFR 1926 Subpart J; 29 CFR 1926.352 and NFPA 51B (35 ft rule also in 1910.252(a)); 29 CFR 1926.152.

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 steel fabrication?

OSHA expects employers to find and control hazards on every job, and many general contractors require a written JHA for steel fabrication 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 steel fabrication?

Usually Welding helmet (ANSI Z87.1), Welding gloves, Safety-toe boots (ASTM F2413), Safety glasses (ANSI Z87.1), Hearing protection (earmuffs or plugs), Coveralls, High-visibility safety apparel, ANSI/ISEA 107 Class 2 or 3 (Type R near roadways), Hard hat (ANSI Z89.1), Work gloves, N95 respirator, Face shield (ANSI Z87.1), Cut-resistant gloves, Half-face respirator (P100 cartridges), Safety goggles (ANSI Z87.1). The site rules may add more, so check with the general contractor.

More welding and fabrication JHAs

JHASteel Erection9 stepsJHAWelding6 stepsJHASteel Beam Installation5 stepsJHASteel Handrail Installation5 stepsJHAOxy Acetylene Cutting5 steps

Related jobs in other trades

RoofingRoof ReplacementAlso involves crane and lifting failurePaintingLead Paint Removal (RRP)Also involves flammable liquids and gasesConcretingConcrete Slab PourAlso involves being hit by heavy equipmentExcavation and earthworksTrenching and ExcavationAlso involves being hit by heavy equipmentElectricalElectrical Panel UpgradeAlso involves cuts from sharp edgesLandscapingTree RemovalAlso involves loud noise

Toolbox talks for this job

Toolbox talkHearing Protection and NoiseToolbox talkPPE: Personal Protective EquipmentToolbox talkHot Works SafetyToolbox talkAngle Grinder Safety

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

Sources