Job Safety Analysis: MIG Welding

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Step Potential Hazard Control
Inspect work area and equipment Fire hazards, poor ventilation, damaged cables, clutter Clear combustibles, improve ventilation, inspect power cords and welding leads, maintain good housekeeping
Prepare and secure materials Hand injuries, sharp edges, dropped objects Wear gloves, use clamps to secure materials, lift with proper technique
Set up MIG welder and gas supply Electric shock, gas leaks, incorrect polarity or settings Verify proper grounding, inspect gas hoses, use leak detection solution, set welder and gas flow to manufacturer specifications
Don PPE and position welding screens Eye injuries, burns, UV exposure to others nearby Use welding helmet, gloves, and flame resistant clothing, place screens to shield bystanders
Begin welding and maintain arc Sparks, molten metal, fumes, burns, fire Maintain safe body position, direct sparks away from combustibles, use local exhaust ventilation or fume extraction
Adjust wire feed or voltage as needed Electric shock, arc flash Make adjustments only when not actively welding, keep hands away from the contact tip
Handle welded materials Burns, dropped materials, sharp edges Allow cooling time, use pliers or gloves rated for heat, clearly mark surfaces that are hot
Shut down welder and gas supply Electric shock, fire hazard, pressure buildup Turn off machine, close gas cylinder valve, bleed pressure from lines, coil cables neatly
Clean work area Fire hazards, trip hazards, leftover metal fragments Remove slag and debris, store tools properly, ensure no smoldering materials remain

Suggested Personal Protective Equipment

  • Welding helmet with proper shade

  • Safety glasses with side shields

  • Flame resistant jacket and pants

  • Welding gloves

  • Steel toe boots

  • Hearing protection

  • Respirator when ventilation is limited or fumes are heavy

  • High visibility vest when welding near vehicles or moving 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:   MIG Welding
Location: __________________________________
Date: ____ /____ /____
Supervisor: __________________________________
Crew: __________________________________
Step Potential Hazard Control
Inspect work area and equipment Fire hazards, poor ventilation, damaged cables, clutter Clear combustibles, improve ventilation, inspect power cords and welding leads, maintain good housekeeping
Prepare and secure materials Hand injuries, sharp edges, dropped objects Wear gloves, use clamps to secure materials, lift with proper technique
Set up MIG welder and gas supply Electric shock, gas leaks, incorrect polarity or settings Verify proper grounding, inspect gas hoses, use leak detection solution, set welder and gas flow to manufacturer specifications
Don PPE and position welding screens Eye injuries, burns, UV exposure to others nearby Use welding helmet, gloves, and flame resistant clothing, place screens to shield bystanders
Begin welding and maintain arc Sparks, molten metal, fumes, burns, fire Maintain safe body position, direct sparks away from combustibles, use local exhaust ventilation or fume extraction
Adjust wire feed or voltage as needed Electric shock, arc flash Make adjustments only when not actively welding, keep hands away from the contact tip
Handle welded materials Burns, dropped materials, sharp edges Allow cooling time, use pliers or gloves rated for heat, clearly mark surfaces that are hot
Shut down welder and gas supply Electric shock, fire hazard, pressure buildup Turn off machine, close gas cylinder valve, bleed pressure from lines, coil cables neatly
Clean work area Fire hazards, trip hazards, leftover metal fragments Remove slag and debris, store tools properly, ensure no smoldering materials remain
Suggested Personal Protective Equipment


Supervisor signature: __________________________________
Employee initials: ______________________________________________________________________________________________________