12 Aug Welding – JSA

Welding Job Safety Analysis (JSA)

Job / Task

Arc welding and related welding activities, including equipment setup, electrode or wire handling, work-area preparation, welding, slag removal, inspection, shutdown, and cleanup.

Purpose

This Job Safety Analysis (JSA), also known as a Job Hazard Analysis (JHA), identifies hazards associated with welding and establishes safe work practices and controls to prevent burns, eye injuries, electric shock, fires, explosions, exposure to welding fumes and gases, compressed-gas hazards, and other welding-related injuries.

Personnel Qualifications

Welding shall be performed only by trained and authorized employees who understand the welding process, equipment, materials, hazards, required PPE, fire-prevention measures, and applicable hot-work procedures.

Employees shall:

• Inspect welding machines, leads, electrode holders, guns, grounding/work leads, cables, connectors, and PPE before use.
• Review the base metal, coatings, consumables, and surrounding conditions for potential fume, fire, explosion, or toxic exposure hazards.
• Obtain a hot-work permit when required by the site or hot-work program.
• Use ventilation, local exhaust, or respiratory protection as required by the hazard assessment.
• Maintain fire prevention controls and required fire watch coverage.
• Protect nearby employees from arc radiation, sparks, slag, and hot metal.
• Follow electrical safety requirements and keep welding equipment dry and properly maintained.
• Stop work when ventilation, fire protection, equipment condition, atmospheric conditions, or other controls are inadequate.

Required PPE

PPE shall be selected for the welding process, amperage, materials, exposure, and work environment and may include:

• Welding helmet or hand shield with the appropriate filter lens shade for the welding operation.
• Safety glasses with side protection worn under the welding helmet.
• Flame-resistant welding gloves.
• Flame-resistant clothing that covers exposed skin and is free of oil, grease, and other combustible contamination.
• Leather sleeves, apron, cape, or other protective clothing where additional protection is needed.
• Safety footwear suitable for hot metal and construction hazards.
• Hearing protection where noise or hot-particle entry into the ear is a hazard.
• Respiratory protection when required by the respiratory hazard assessment and respiratory-protection program.
• Hard hat where overhead or construction hazards exist.
• Additional task-specific PPE identified by the hazard assessment.

Clothing shall be arranged to prevent sparks and hot metal from becoming trapped in cuffs, pockets, openings, or footwear. Synthetic clothing that can melt shall not be used where it increases burn risk.

JSA – Job Steps, Hazards, and Controls

Step 1 – Review the Welding Task

Potential Hazards

• Unknown materials or coatings.
• Incorrect welding process.
• Toxic fumes.
• Fire or explosion hazards.

Required Controls

• Identify the welding process, base metal, consumables, coatings, and work location before beginning.
• Review applicable SDS information and manufacturer instructions.
• Determine ventilation, respiratory protection, fire prevention, electrical protection, and PPE requirements.
• Remove coatings from the weld area when necessary and safe to do so.
• Do not weld on materials of unknown composition when hazardous exposures cannot be evaluated.

Step 2 – Inspect the Work Area

Potential Hazards

• Combustible materials.
• Flammable vapors.
• Poor ventilation.
• Nearby personnel exposure.

Required Controls

• Inspect the area for combustible materials, flammable liquids, gases, dusts, and other ignition hazards.
• Relocate combustibles when practical or protect them with suitable fire-resistant barriers or covers.
• Do not weld where flammable or explosive atmospheres may exist unless specifically controlled and authorized.
• Evaluate openings, cracks, floors, walls, and concealed spaces where sparks or heat could travel.
• Control access and protect nearby employees.

Step 3 – Obtain Hot-Work Authorization

Potential Hazards

• Uncontrolled ignition sources.
• Inadequate fire protection.
• Work in prohibited area.

Required Controls

• Obtain and complete the required hot-work permit before welding where applicable.
• Verify required precautions are in place before work begins.
• Confirm fire-extinguishing equipment is immediately available.
• Assign a trained fire watch when required.
• Suspend work if permit conditions or required controls cannot be maintained.

Step 4 – Inspect Welding Equipment

Potential Hazards

• Electric shock.
• Damaged cables.
• Equipment malfunction.
• Fire.

Required Controls

• Inspect the welding machine, electrode holder or gun, cables, connectors, work lead, plugs, and controls before use.
• Remove damaged insulation, exposed conductors, loose connections, or defective equipment from service.
• Ensure equipment is properly installed and used according to manufacturer instructions.
• Keep cables clear of sharp edges, hot surfaces, standing water, and vehicle traffic.
• Do not use makeshift electrical repairs.

Step 5 – Establish the Welding Circuit

Potential Hazards

• Electric shock.
• Poor connection.
• Overheating.
• Stray welding current.

Required Controls

• Attach the work lead as close to the weld as practical to provide an effective current path.
• Ensure connections are secure and appropriate for the equipment.
• Do not attach welding return connections to piping, chains, wire rope, or other unintended conductive paths.
• Keep the electrode holder or gun insulated from grounded surfaces when not in use.
• Do not coil welding cables around the body.

Step 6 – Set Up Ventilation

Potential Hazards

• Welding fumes.
• Metal fumes.
• Shielding gases.
• Oxygen displacement.

Required Controls

• Provide adequate natural, mechanical, or local exhaust ventilation based on the process, materials, and work location.
• Position local exhaust to capture fumes near their source without disrupting shielding gas where applicable.
• Keep the welder’s breathing zone out of the fume plume whenever practical.
• Use respiratory protection when engineering and work-practice controls do not adequately control exposure and when required by the respiratory-protection program.
• Do not use oxygen for ventilation.

Step 7 – Install Screens and Barriers

Potential Hazards

• Arc-eye exposure.
• Skin burns from ultraviolet radiation.
• Sparks striking others.

Required Controls

• Use noncombustible or flame-resistant welding screens or curtains to protect nearby employees.
• Position barriers so they do not create ventilation or access hazards.
• Warn nearby personnel before striking an arc.
• Require appropriate eye protection for persons who must observe welding.
• Maintain barriers throughout the welding operation.

Step 8 – Prepare the Workpiece

Potential Hazards

• Sharp edges.
• Hot work on contaminated surfaces.
• Toxic coating fumes.
• Unexpected movement.

Required Controls

• Secure the workpiece against movement.
• Remove oil, grease, paint, coatings, residues, or contamination as necessary for safe welding.
• Use appropriate controls when removing hazardous coatings.
• Identify hollow or enclosed components that may contain pressure, vapors, or residues.
• Do not weld on containers or equipment that have held flammable or hazardous materials until properly cleaned, isolated, tested, and authorized.

Step 9 – Perform Welding

Potential Hazards

• Arc radiation.
• Burns.
• Electric shock.
• Sparks and slag.
• Welding fumes.

Required Controls

• Wear all required welding PPE before striking the arc.
• Maintain dry gloves and clothing and avoid contact with energized electrode components and the workpiece at the same time.
• Keep the welding helmet down during arc exposure.
• Maintain ventilation and keep the head out of the fume plume.
• Control sparks and slag and continuously observe surrounding conditions for fire hazards.
• Stop welding immediately if equipment, ventilation, fire protection, or environmental conditions become unsafe.

Step 10 – Weld in Wet or Damp Conditions

Potential Hazards

• Severe electric shock.
• Damaged equipment.
• Wet PPE.

Required Controls

• Avoid welding in wet or damp conditions whenever practical.
• Keep welding machines, connections, electrode holders, and cables dry and protected.
• Do not use wet gloves or clothing.
• Use insulating platforms or mats where required and appropriate.
• Stop work when water or moisture creates an uncontrolled electrical hazard.

Step 11 – Weld in Confined or Enclosed Spaces

Potential Hazards

• Toxic atmosphere.
• Oxygen deficiency or enrichment.
• Fume accumulation.
• Fire.
• Difficult rescue.

Required Controls

• Follow the applicable confined-space program when the location meets confined-space criteria.
• Test and monitor the atmosphere as required.
• Provide adequate ventilation and maintain gas cylinders outside confined spaces unless specifically permitted and controlled.
• Provide an attendant and rescue provisions when required.
• Remove welding equipment or otherwise prevent unintended gas release when work is suspended.

Step 12 – Control Compressed-Gas Hazards, When Applicable

Potential Hazards

• Cylinder damage.
• Gas leak.
• Fire or explosion.
• High-pressure release.

Required Controls

• Secure cylinders upright and protect them from physical damage, heat, sparks, and electrical circuits.
• Keep valve protection caps in place when cylinders are not connected for use.
• Inspect regulators, hoses, valves, and connections before use.
• Keep oxygen equipment free from oil and grease.
• Close cylinder valves when work is complete or equipment is unattended as required.

Step 13 – Remove Slag and Clean the Weld

Potential Hazards

• Flying particles.
• Hot slag.
• Burns.
• Noise.

Required Controls

• Allow material to cool when practical before handling.
• Wear safety glasses and face protection as appropriate during chipping, brushing, or grinding.
• Direct flying particles away from personnel and combustible materials.
• Use guarded tools in accordance with manufacturer instructions.
• Treat recently welded metal as hot until verified otherwise.

Step 14 – Inspect Completed Work

Potential Hazards

• Contact with hot metal.
• Sharp edges.
• Residual fire hazard.

Required Controls

• Use visual indicators, barriers, or other methods to identify hot material when others may contact it.
• Inspect the weld and surrounding area from a safe position.
• Correct sharp edges or protrusions when required.
• Continue monitoring for smoldering material or hidden ignition.
• Do not remove fire controls prematurely.

Step 15 – Shut Down Welding Equipment

Potential Hazards

• Electric shock.
• Hot equipment.
• Fire.
• Uncontrolled gas release.

Required Controls

• Turn off welding equipment in accordance with manufacturer instructions.
• Place electrode holders or guns where they cannot make unintended electrical contact.
• Disconnect or isolate power when required before maintenance or relocation.
• Close compressed-gas cylinder valves and relieve system pressure as applicable.
• Allow hot equipment and workpieces to cool before storage or handling.

Step 16 – Complete Fire Watch and Cleanup

Potential Hazards

• Delayed fire.
• Hot slag in concealed areas.
• Combustible waste ignition.

Required Controls

• Maintain the fire watch for the period required by the hot-work program and site conditions.
• Inspect adjacent areas, lower levels, opposite sides of walls, and concealed spaces that may have received sparks or heat.
• Remove electrode stubs, slag, metal scraps, and combustible waste.
• Return extinguishers and protective equipment to designated locations.
• Report fires, near misses, equipment defects, and unusual exposures.

General Safe Work Requirements

• Welding shall be performed only by trained and authorized employees.
• A hot-work permit shall be obtained whenever required by the applicable hot-work program or site requirements.
• Combustible and flammable materials shall be removed, isolated, or protected from sparks, slag, and heat.
• Suitable fire-extinguishing equipment shall be readily available, and a fire watch shall be provided when required.
• Employees and nearby personnel shall be protected from arc radiation, sparks, and hot metal.
• Adequate ventilation shall be provided to control welding fumes and gases.
• Respiratory protection shall be used when required by the exposure assessment and respiratory-protection program.
• Welding equipment, cables, electrode holders, guns, and connections shall be inspected and maintained in safe condition.
• Containers, tanks, piping, or equipment that contained flammable or hazardous substances shall not be welded until properly cleaned, isolated, tested, and authorized.
• Work shall stop whenever electrical, atmospheric, fire, equipment, or ventilation hazards cannot be adequately controlled.

Training

Employees performing welding shall receive training appropriate to the processes and equipment used. Training shall include welding hazards, electrical safety, PPE and filter-lens selection, hot-work permits, fire prevention and fire-watch duties, welding fumes and ventilation, hazardous coatings and metals, compressed-gas safety where applicable, confined-space requirements, equipment inspection, emergency response, and stop-work expectations.

References

• OSHA 29 CFR 1926 Subpart J – Welding and Cutting.
• OSHA 29 CFR 1926.351 – Arc Welding and Cutting.
• OSHA 29 CFR 1926.352 – Fire Prevention.
• OSHA 29 CFR 1926.353 – Ventilation and Protection in Welding, Cutting, and Heating.
• OSHA 29 CFR 1910 Subpart Q – Welding, Cutting, and Brazing, where applicable.
• OSHA 29 CFR 1910.134 – Respiratory Protection, where applicable.
• Applicable SDSs, manufacturer instructions, hot-work procedures, and site requirements.