Job Safety Analysis: Stick Welding

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Step Potential Hazard Control
Inspect work area and equipment Fire hazards, poor ventilation, damaged cables, exposed conductors Remove combustibles, improve ventilation, inspect stinger, leads, and power cord for defects
Prepare materials and work surface Sharp edges, dropped materials, pinch points Wear gloves, secure work with clamps, maintain clean and stable working area
Set up welder and attach work lead Electric shock, incorrect polarity, loose connections Verify proper grounding, check polarity settings, ensure work clamp is secure
Install welding electrode Burns, electric shock Turn machine off or ensure output is disabled during installation, wear gloves
Position welding screens and don PPE UV exposure, eye injury to others, burns Use welding helmet and protective clothing, place screens to shield coworkers or bystanders
Begin welding and maintain arc Arc flash, sparks, molten metal, slag, fumes, fire Keep proper arc length, direct sparks away from combustibles, use ventilation or fume extraction, keep fire extinguisher available
Chip slag and inspect weld Eye injury, flying debris, sharp edges Wear safety glasses and face shield, keep hands clear, use proper chipping tools
Handle hot welded materials Burns, dropped items, sharp edges Allow cooling time, use pliers or tongs, mark hot materials to warn others
Shut down equipment Electric shock, fire risk Turn off welder, remove electrode, coil and store leads properly
Clean and inspect work area Fire hazards, trip hazards, leftover slag or metal pieces Remove debris, confirm no smoldering materials remain, restore tools and equipment

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 for limited ventilation or when 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:   Stick Welding
Location: __________________________________
Date: ____ /____ /____
Supervisor: __________________________________
Crew: __________________________________
Step Potential Hazard Control
Inspect work area and equipment Fire hazards, poor ventilation, damaged cables, exposed conductors Remove combustibles, improve ventilation, inspect stinger, leads, and power cord for defects
Prepare materials and work surface Sharp edges, dropped materials, pinch points Wear gloves, secure work with clamps, maintain clean and stable working area
Set up welder and attach work lead Electric shock, incorrect polarity, loose connections Verify proper grounding, check polarity settings, ensure work clamp is secure
Install welding electrode Burns, electric shock Turn machine off or ensure output is disabled during installation, wear gloves
Position welding screens and don PPE UV exposure, eye injury to others, burns Use welding helmet and protective clothing, place screens to shield coworkers or bystanders
Begin welding and maintain arc Arc flash, sparks, molten metal, slag, fumes, fire Keep proper arc length, direct sparks away from combustibles, use ventilation or fume extraction, keep fire extinguisher available
Chip slag and inspect weld Eye injury, flying debris, sharp edges Wear safety glasses and face shield, keep hands clear, use proper chipping tools
Handle hot welded materials Burns, dropped items, sharp edges Allow cooling time, use pliers or tongs, mark hot materials to warn others
Shut down equipment Electric shock, fire risk Turn off welder, remove electrode, coil and store leads properly
Clean and inspect work area Fire hazards, trip hazards, leftover slag or metal pieces Remove debris, confirm no smoldering materials remain, restore tools and equipment
Suggested Personal Protective Equipment


Supervisor signature: __________________________________
Employee initials: ______________________________________________________________________________________________________