First, describe the work and worksite
Fictional example: a construction crew will cut new, identified uncoated mild-steel brackets with oxy-fuel equipment, then weld them at a ground-level outdoor fabrication station. A delivery route and combustible packaging are nearby. The work excludes vessels, used containers, structural demolition, confined spaces, and unknown coatings. No inspection or permit has been completed by this example; the responsible supervisor must establish the actual conditions before authorizing work.
- Record the welding process, base metal, filler, coatings, equipment models, and applicable safety data sheets. A change to galvanized or stainless material requires reassessment.
- The station has a firm working surface and an exclusion area that can keep deliveries, pedestrians, and other trades outside the hot-work exposure.
- Identify the hot-work authorization process, trained operators, fire-watch coverage, suitable extinguishers, emergency contact method, and the person responsible for closing the work.
- Outdoor air movement is variable. The exposure assessment must consider nearby workers as well as the welder; being outside does not establish adequate fume control.
Build the analysis one step at a time
What will the worker do? How could someone be harmed? What prevents or reduces that exposure? Who checks the control, and when?
Confirm material and work boundaries
Hazard: An unidentified coating or residue releases hazardous contaminants when heated; a nearby flammable process ignites.
Control: The supervisor verifies the material and process information before selecting controls. Move hot work to the designated station. Stop when material identity or previous contents are unknown.
Verification: Identify the material record and inspect both the workpiece and surrounding operations; resolve discrepancies before hot work.
Why this belongs in the analysis: The same torch can create very different exposures on clean steel, coated steel, and a used container.
Prepare the fire-control area
Hazard: Sparks, slag, or conducted heat reach packaging, hidden openings, or people beyond the visible workface.
Control: Remove movable combustibles; protect remaining exposures with suitable barriers. Examine openings and opposite surfaces. Assign a trained fire watch where normal precautions are insufficient and make suitable extinguishing equipment immediately available.
Verification: The supervisor and fire watch walk the exposure area, identify alarm and evacuation actions, and record the required watch and follow-up periods.
Why this belongs in the analysis: A clear tabletop is insufficient when hot particles or heat can travel beyond it.
Set up welding and gas equipment
Hazard: Damaged leads cause electric shock; a falling cylinder or leaking hose releases fuel or oxygen.
Control: Inspect leads, holders, return connections, hoses, regulators, and torches. Remove defective items. Secure cylinders upright and protect them from heat and impact. Keep oxygen equipment free of oil and grease; route leads and hoses away from traffic.
Verification: The operator checks the specific equipment instructions and verifies safe isolation and shutdown methods before connection.
Why this belongs in the analysis: An equipment inspection connects the generic JSA to the actual machine and gas set being used.
Establish fume, radiation, and personal protection
Hazard: Fumes enter breathing zones; the arc or hot metal burns eyes and skin of workers and passersby.
Control: Select ventilation from the material/process exposure assessment; position source capture when needed without directing contaminants at others. Install welding screens. Select appropriate filter shade, eye protection, gloves, protective clothing, and hearing protection. Use respirators only through the required respiratory-protection program.
Verification: The designated exposure assessor confirms control selection; operators verify screen coverage and ventilation performance using the established assessment method.
Why this belongs in the analysis: A helmet protects the wearer from the arc but does not establish protection against airborne contaminants.
Cut and weld the secured workpiece
Hazard: Unsupported offcuts fall, hands enter pinch points, or changing conditions defeat the fire and fume controls.
Control: Support and restrain the workpiece and offcuts before cutting. Keep people outside the spark and drop zones. Maintain the selected controls throughout work; stop for a gas leak, failed extraction, encroachment, or unsafe weather.
Verification: The operator checks supports before each cut and confirms fire-watch availability and protection of adjacent workers.
Why this belongs in the analysis: Securing an offcut before separation prevents an otherwise predictable falling-object event.
Shut down and close the hot work
Hazard: Residual heat ignites concealed material after departure; hot steel burns another worker; gas remains available at damaged equipment.
Control: Shut equipment down using its instructions, close cylinder valves, and secure the station. Mark or segregate hot pieces. Continue the assigned watch and follow-up inspection for the period required by conditions, the permit, and applicable rules.
Verification: The responsible person records the actual shutdown, watch completion, inspection findings, and unresolved conditions; do not prefill a clearance.
Why this belongs in the analysis: The JSA continues after the arc stops because the ignition source may persist.
What does a useful control look like?
| Needs improvement | More useful for this scenario |
|---|---|
| Fire: have an extinguisher. | Trace where sparks and heat can travel, remove combustibles, assign necessary watch coverage, and verify extinguishing readiness. |
| Fumes: wear a mask. | Identify the metal and process, assess exposure, select ventilation, and determine whether a respiratory-protection program is needed. |
Decisions that change the analysis
A painted bracket arrives. Can the crew use this example unchanged?
Stop and identify the coating and exposure implications. Confirm removal or other controls before revising the analysis.
The fire watch is called elsewhere. What happens?
Suspend work that depends on that watch until a trained replacement receives the handover and required coverage is restored.
Agree when the crew will pause
- Pause for a different alloy/coating, enclosure, ventilation failure, flammable process, or unknown container history.
- Reassess when sparks can reach another level, the watch is relieved, or weather changes the work area.
After a pause, correct the condition, reassess the work, and obtain required authorization before restarting. Keep unresolved actions visible.
Download the worked example and free template
No account or paid membership required. The worked example contains planned controls. The blank template is for your own work; neither includes fabricated inspection results, signatures or approval.
Your editable working copy
Build and download your draft
Start blank or load the learning example. Replace its assumptions with your actual conditions and involve the people doing the work. Your entries stay in this browser tab; download a copy before leaving or refreshing.
1. Describe your work and site
2. Work through each task
Describe an observable step, how someone could be harmed, and the control that acts on that hazard. Identify who checks it and what evidence is needed.
3. Record changes, checks, and open actions
Walk the work area, review with the crew, and resolve missing controls. Follow the required approval process. This tool does not judge completeness, verify signatures or authorize work.
Open the downloaded file in a browser, then use Print → Save as PDF for a printable copy.
Common questions
Is a 30-minute fire watch always enough?
No. Federal construction rule 1926.352(e) requires a sufficient period after work to address the fire possibility; permits, adopted fire codes, and site conditions can require more. Establish and record the applicable period.
Does this replace a hot-work permit?
No. It explains the task hazards and planned controls. Complete any required permit and equipment-specific procedure separately, then cross-reference them in the site analysis.
Are these resources part of a paid course?
This walkthrough, browser draft builder and downloads are free public resources, separate from Academy course enrollment.
References and source note
- OSHA 1926.350: Gas welding and cutting
- OSHA 1926.351: Arc welding and cutting
- OSHA 1926.352: Fire prevention
- OSHA 1926.353: Ventilation and protection
This original walkthrough was informed by review of uploaded examples, then rewritten for the stated fictional scenario using current primary references. It does not reproduce a source document or its approval record. Use actual equipment instructions and site requirements alongside these references. Reference review: October 6, 2026.