Welding hazards go beyond the obvious burn risk. Fume exposure, radiation (both UV and IR), electrical shock, hot work fire hazards, and confined space asphyxiation — welding JHAs need to address all of it, not just "wear a welding helmet."
Process-Specific Hazards
- SMAW (stick) — high radiation, flux fume, spatter
- GMAW (MIG) — shielding gas asphyxiation risk in confined space, ozone generation
- GTAW (TIG) — thoriated tungsten radiation, high-intensity UV
- FCAW (flux-core) — heaviest fume of any process
- SAW (submerged arc) — flux dust inhalation, high current shock risk
Fume Hazards By Material
Metal fume is not created equal. Some materials generate significantly more hazardous fumes:
- Galvanized steel — zinc fume, causes metal fume fever
- Stainless steel — hexavalent chromium (carcinogen), OSHA has specific standard
- Cadmium plating — extremely toxic, requires respiratory protection
- Lead-painted steel — lead exposure, blood testing required
- Aluminum — ozone from arc
Written JHA Elements For Welding
- Task description and specific process(es)
- Material being welded (base metal, filler, coating)
- Location and adjacent operations
- Fire hazards within 35 feet and controls
- Ventilation — natural, local exhaust, or respirator
- PPE — welding hood shade #, gloves, jacket, boots
- Electrical safety — grounding, cable inspection
- Confined space evaluation if applicable
- Hot work permit if applicable
- Fire watch requirements
What's In The Forbes Welding JHA Pack
- SMAW welding JHA
- GMAW/FCAW welding JHA
- GTAW welding JHA
- Welding in confined space JHA
- Welding on coated materials JHA
- Hexavalent chromium exposure plan
- Welder training documentation
- Hot work permit template
Get The Template Now — Priced For The Crew, Not The Consultant
Instant download. Editable Word + PDF. From $3.99. No subscriptions. No BS.
Frequently Asked Questions
What welding hood shade should I use?
OSHA 1910.252 Table Q-1 provides recommended shades. Common: SMAW at 60-160 amps = shade 10-11; GMAW at 60-160 amps = shade 11-12; GTAW at 20-100 amps = shade 10-11. Higher amperage = higher shade number. Auto-darkening hoods are standard now but must have correct max shade rating for your work.
Do I need respiratory protection for welding?
Depends on material and ventilation. Stainless steel welding requires respiratory protection under 1910.1026 (hexavalent chromium) unless engineering controls demonstrably keep exposures below PEL. Galvanized welding requires protection when zinc fume exposure exceeds limits. Mild steel with adequate ventilation often doesn't require respirator, but air sampling should verify.
What's hexavalent chromium and when do I need to worry about it?
Cr(VI) is a carcinogen generated when welding stainless steel and some high-nickel alloys. OSHA 1910.1026 specifies exposure limits, required air monitoring, medical surveillance, and respiratory protection. Serious stainless welding operations MUST have a written chromium exposure control program.
Can I weld in a confined space?
Yes, but requires combined confined space + hot work permits, atmospheric testing for oxygen and flammables, continuous ventilation, and typically supplied air respirators due to fume accumulation. Standard cartridge respirators aren't adequate for extended welding in confined space.
What's the biggest welding safety citation risk?
Failure to have hot work permits and fire watch for welding outside designated welding areas. Second is missing respiratory protection for hexavalent chromium exposure during stainless steel welding. Both are commonly cited and both are avoidable with a written program.
Do welders need annual training?
Not explicitly required by OSHA, but AWS certifications require periodic retesting. Employer training on hazards should be refreshed when processes change, incidents occur, or when workers demonstrate knowledge gaps. Annual refresher is best practice.