Job Safety Analysis: Arc Welding

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Step Potential Hazard Control
Inspect work area and equipment Fire hazards, poor ventilation, damaged cables or stingers Remove combustibles, verify good ventilation, inspect leads and electrode holder for wear or damage
Prepare materials and work area Sharp edges, pinched fingers, dropped materials Wear gloves, secure materials with clamps, maintain good housekeeping
Set up machine and attach work lead Electric shock, incorrect polarity, loose connections Ensure proper grounding, verify polarity, inspect work clamp and connections
Install welding electrode Electric shock, burns Wear gloves, install electrode with machine turned off or output disabled
Position welding screens and don PPE UV exposure, eye injury, burns Use welding helmet, gloves, and flame resistant clothing, place screens to protect bystanders
Begin welding and maintain arc Sparks, molten metal, slag, fumes, fire Maintain proper distance, keep sparks away from combustibles, use ventilation or fume extraction, keep a fire extinguisher nearby
Chip slag and inspect weld Eye injury, flying debris, sharp edges Wear safety glasses and face shield, use proper tools, keep hands clear
Handle welded materials Burns, dropped objects, sharp edges Allow cooling or use pliers, mark hot materials, lift properly
Shut down equipment Electric shock, fire hazard Turn off machine, disconnect or store leads, remove electrode from holder
Clean work area Fire hazards, trip hazards, leftover slag or scrap Remove debris, verify there are no smoldering materials, store tools and equipment properly

Suggested Personal Protective Equipment

  • Welding helmet with proper shade

  • Safety glasses with side shields

  • Flame resistant welding jacket and pants

  • Leather welding gloves

  • Steel toe boots

  • Hearing protection

  • Respirator if ventilation is limited or welding on coated metals

  • High visibility vest when working near vehicles or equipment

Always have a complete, well-stocked first aid kit available.

JSA Category: General Maintenance and Shop Operations

* The steps, hazards, and controls displayed above may be incomplete or not suit your department's needs. All job safety analyses should be a completed with frontline worker input to ensure that each potential hazard is identified and mitigated.

Please read about The Essentials Elements of a Solid Job Safety Anaylsis here.

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Job Safety Analysis
Department: __________________________________
Job/Task:   Arc Welding
Location: __________________________________
Date: ____ /____ /____
Supervisor: __________________________________
Crew: __________________________________
Step Potential Hazard Control
Inspect work area and equipment Fire hazards, poor ventilation, damaged cables or stingers Remove combustibles, verify good ventilation, inspect leads and electrode holder for wear or damage
Prepare materials and work area Sharp edges, pinched fingers, dropped materials Wear gloves, secure materials with clamps, maintain good housekeeping
Set up machine and attach work lead Electric shock, incorrect polarity, loose connections Ensure proper grounding, verify polarity, inspect work clamp and connections
Install welding electrode Electric shock, burns Wear gloves, install electrode with machine turned off or output disabled
Position welding screens and don PPE UV exposure, eye injury, burns Use welding helmet, gloves, and flame resistant clothing, place screens to protect bystanders
Begin welding and maintain arc Sparks, molten metal, slag, fumes, fire Maintain proper distance, keep sparks away from combustibles, use ventilation or fume extraction, keep a fire extinguisher nearby
Chip slag and inspect weld Eye injury, flying debris, sharp edges Wear safety glasses and face shield, use proper tools, keep hands clear
Handle welded materials Burns, dropped objects, sharp edges Allow cooling or use pliers, mark hot materials, lift properly
Shut down equipment Electric shock, fire hazard Turn off machine, disconnect or store leads, remove electrode from holder
Clean work area Fire hazards, trip hazards, leftover slag or scrap Remove debris, verify there are no smoldering materials, store tools and equipment properly
Suggested Personal Protective Equipment


Supervisor signature: __________________________________
Employee initials: ______________________________________________________________________________________________________