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Drawn Arc Shear Stud Welding JHA
A JHA breaks the work into steps, hazards and controls. Use this example to build a draft for your actual job and review it with your crew.
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Step 1 of 4 · Working draft
Your job
Tell Jenkins what you’re planning and where the work will happen. Use the actual job details.
Use the published example’s suggestions when they fit your task, or write your own steps. These are planned controls, not verified worksite conditions.
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.
Walk through the plan with the people doing the work. Resolve missing controls and agree who checks them. Moving to the next step does not approve the work.
Confirm people, equipment and emergency arrangements
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.
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Your Drawn Arc Shear Stud Welding JHA
Walk through the job in order. Use these possible hazards, planned controls and checks to start a conversation about your actual work.
011. Release the platform and connector detail
Possible hazards: Installing projecting studs too early creates trip/fall hazards and can violate the required deck-first sequence.
Planned controls: Welding lead confirms the installed deck’s accepted work-platform condition, protected openings and conventional fall protection. Review the current connector layout and procedure; do not begin on undecked beam tops or within a controlled decking zone.
Check before work: Lead checks platform readiness and the connector documents before layout starts.
022. Establish the hot-work and exposure boundary
Possible hazards: Stud arcs and hot metal can ignite material below or expose nearby people to radiation and fumes.
Planned controls: Complete the actual hot-work review for both sides of the deck and adjacent areas. Remove or protect combustibles, provide the required fire watch and extinguisher readiness, screen others from arc radiation and establish suitable fume controls for the identified material/configuration.
Check before work: Hot-work lead and assigned fire watch check both-level protection and response arrangements.
033. Verify the stud-welding system
Possible hazards: An incompatible gun/ferrule or defective electrical circuit can injure workers and produce inadequate welds.
Planned controls: Qualified operator checks the actual power source, gun, cable/return connections, chuck and ferrule selection against the approved procedure and manufacturer instructions. Keep equipment suitable for the conditions and leads clear of routes; isolate before permitted setup changes and remove defective equipment from service.
Check before work: Operator records the equipment match and pre-use findings; lead resolves discrepancies.
044. Establish the required initial acceptance
Possible hazards: An unverified first setup can repeat defective welds throughout a floor.
Planned controls: Carry out the procedure’s required preproduction or initial verification with the designated competent inspection roles. Record actual results against the specified criteria and hold production when requirements are unmet. Apply authorized corrective decisions; do not invent a test count, bend angle or acceptance value.
Check before work: Designated reviewer confirms actual initial results before releasing continued production.
055. Weld the released connector layout
Possible hazards: Hot ferrules, arc exposure and protruding studs can injure workers as the pattern advances.
Planned controls: Operator welds the specified studs using the released procedure, protected stance and matched equipment. Maintain fire/fume controls and check the required ongoing weld conditions. Control access through completed stud areas and collect cooled ferrule debris with suitable protection; pause for unstable footing or abnormal equipment/weld behavior.
Check before work: Welding lead checks production observations and the changing trip/access boundary.
066. Inspect, close hot work and hand over
Possible hazards: Unrecorded rejected welds or early closeout can leave structural defects and a later fire or trip hazard.
Planned controls: Complete the specified inspection and correction records and identify open weld actions. Shut down the equipment safely, maintain the fire watch for the actual required period and clear cooled debris. Hand over connector acceptance and protected routes without removing unrelated frame restraint.
Check before work: Responsible reviewer records weld disposition; hot-work lead confirms actual closeout conditions.
Example scope and starting conditions
A specialist welding crew will install specified headed shear connectors on a composite building floor using a selected drawn-arc stud-welding system. Metal decking is already installed and released as the walking platform; conventional fall protection and hot-work controls are maintained. The approved connection detail and stud-welding procedure govern the actual equipment setup and weld acceptance. This fictional learning example describes planned controls; it records no actual inspection or work authorization.
- Shear connectors are laid out and installed after the metal-deck work platform is installed; this operation is not performed from a controlled decking zone.
- The actual stud, ferrule, gun, power source, base/deck configuration, coating condition and welding/inspection procedure are identified for the project.
- This is partial structural field-welding coverage. Generic structural connection welds, deck-panel welding, undecked beam walking, confined-space work and unassessed coatings are excluded.
Know when to pause
- The deck platform, opening protection or conventional fall-protection arrangement is no longer released for the work.
- Stud, ferrule, base/deck condition or welding setup differs from the approved procedure, or required acceptance results fail.
- Fire watch, electrical condition, fume protection or safe access around projecting studs cannot be maintained.
After a pause, correct the condition, reassess the work, and obtain required authorization before restarting.
Free example and template
No account required. The worked example contains planned controls. The blank template is for your own work; neither includes fabricated inspection results, signatures or approval.
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For managers
Does the team have what it needs to carry out the plan? Give the crew time, equipment and support, and make it clear who will resolve anything that is missing.
Manager checks and supporting resources
Confirm the people doing the work have the time, equipment, information and support to carry out the plan. Agree who checks the controls and who resolves open actions.
Questions to resolve before work
- What evidence releases the metal deck, openings and fall-protection arrangement as the stud-welding work platform?
- Which approved stud-welding procedure and inspection criteria apply to the actual stud/deck/base configuration?
- How will sparks, heat and fume exposures be controlled on this level and below the weld location?
Training and qualifications to confirm
- Procedure- and equipment-specific drawn-arc stud-welding instruction and the required operator/inspection qualifications, including setup verification and response to a rejected weld.
- Training in electrical equipment checks, arc protection, fire-watch duties and safe access around newly installed projecting studs.
Confirm the actual training evidence for the assigned people. A toolbox talk does not establish competence.
Decisions that change the plan
Does ordinary structural field welding or metal-deck installation already cover this operation?
No. The deck example expressly excludes shear studs, and the structural weld example joins ordinary frame connections. This resource teaches the specialized drawn-arc composite-connector workflow, deck-first prerequisite and procedure-specific initial and ongoing acceptance.
What must the crew record for actual use?
Record the platform and access release, connector layout/procedure revisions, stud/ferrule and equipment identities, material/coating findings, operator/inspection roles, hot-work and fume arrangements, actual initial and production inspection results, weld corrections and closeout findings.
Keep planning connected
Resources that support this JHA
Additional tools for task planning and safe work. Start with the free resources; explore paid options only when they meet an additional need.
Toolbox talks for the work
Prepare a practical crew discussion.
Hot Work: Verify the Area and Fire Watch →Fall Prevention: Verify the Controls →Electrical & Extension-Cord Checks →
Safety program resources
Review procedures, roles, and requirements.
Browse the existing catalog and confirm the scope and purchase availability of each program.
Browse safety programs →
Paid service · Availability
Task-specific training and qualifications
Explore applicable training and qualification needs.
Task-specific training services are not currently available to book here. Start with the free training-needs lookup; a toolbox talk or online course alone does not establish competence or employer authorization.
Review training needs · Free →People, equipment, emergency arrangements and open actions are recorded in the guided JHA’s Crew review step.
Open the crew review step →For safety professionals
How do we know the planning process and controls are working? Connect what the crew reports with field checks, risk decisions and the evidence behind your system.
Industry context, SIF, control verification and AHA review
Guidance and evidence
Review the method, risk decisions and evidence behind the plan. Use the actual jurisdiction, equipment instructions, employer process and project requirements.
Task-by-task control and verification rationale
1. Release the platform and connector detail
Hazard: Installing projecting studs too early creates trip/fall hazards and can violate the required deck-first sequence.
Control: Welding lead confirms the installed deck’s accepted work-platform condition, protected openings and conventional fall protection. Review the current connector layout and procedure; do not begin on undecked beam tops or within a controlled decking zone.
Verification: Lead checks platform readiness and the connector documents before layout starts.
Why this belongs in the analysis: Shear-connector installation has a specific work-platform prerequisite.
2. Establish the hot-work and exposure boundary
Hazard: Stud arcs and hot metal can ignite material below or expose nearby people to radiation and fumes.
Control: Complete the actual hot-work review for both sides of the deck and adjacent areas. Remove or protect combustibles, provide the required fire watch and extinguisher readiness, screen others from arc radiation and establish suitable fume controls for the identified material/configuration.
Verification: Hot-work lead and assigned fire watch check both-level protection and response arrangements.
Why this belongs in the analysis: A clear upper surface does not show the concealed ignition or exposure hazards below.
3. Verify the stud-welding system
Hazard: An incompatible gun/ferrule or defective electrical circuit can injure workers and produce inadequate welds.
Control: Qualified operator checks the actual power source, gun, cable/return connections, chuck and ferrule selection against the approved procedure and manufacturer instructions. Keep equipment suitable for the conditions and leads clear of routes; isolate before permitted setup changes and remove defective equipment from service.
Verification: Operator records the equipment match and pre-use findings; lead resolves discrepancies.
Why this belongs in the analysis: Drawn-arc setup is specific to the connector and configuration, not a universal setting.
4. Establish the required initial acceptance
Hazard: An unverified first setup can repeat defective welds throughout a floor.
Control: Carry out the procedure’s required preproduction or initial verification with the designated competent inspection roles. Record actual results against the specified criteria and hold production when requirements are unmet. Apply authorized corrective decisions; do not invent a test count, bend angle or acceptance value.
Verification: Designated reviewer confirms actual initial results before releasing continued production.
Why this belongs in the analysis: The verification must demonstrate this setup’s performance before it is repeated.
5. Weld the released connector layout
Hazard: Hot ferrules, arc exposure and protruding studs can injure workers as the pattern advances.
Control: Operator welds the specified studs using the released procedure, protected stance and matched equipment. Maintain fire/fume controls and check the required ongoing weld conditions. Control access through completed stud areas and collect cooled ferrule debris with suitable protection; pause for unstable footing or abnormal equipment/weld behavior.
Verification: Welding lead checks production observations and the changing trip/access boundary.
Why this belongs in the analysis: A growing stud pattern changes the walking surface during the operation.
6. Inspect, close hot work and hand over
Hazard: Unrecorded rejected welds or early closeout can leave structural defects and a later fire or trip hazard.
Control: Complete the specified inspection and correction records and identify open weld actions. Shut down the equipment safely, maintain the fire watch for the actual required period and clear cooled debris. Hand over connector acceptance and protected routes without removing unrelated frame restraint.
Verification: Responsible reviewer records weld disposition; hot-work lead confirms actual closeout conditions.
Why this belongs in the analysis: A completed stud count is not evidence of accepted welds or a cleared fire hazard.
Compare control wording
| Needs improvement | More useful for this scenario |
|---|---|
| Use the same settings as the last job. | Qualified operator matches the stud, ferrule and actual deck/base configuration to the approved procedure, then records the required initial verification. |
| The studs are all in; the job is done. | Responsible reviewer records weld acceptance and open corrections; hot-work lead confirms fire-watch closeout and the crew hands over safe routes through the stud pattern. |
Common questions
Can this example be used as a JSA?
Adapt its Task | Hazard | Control analysis to the employer’s JSA format and the actual work. Confirm the assigned checks and record real findings before relying on the plan.
What changes if the project requires an AHA?
Use the project’s governing AHA format, risk method, supporting records and acceptance process. The published formwork AHA illustrates that additional structure; this JHA does not establish an AHA risk rating or acceptance.
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 1926.754(c) Shear connectors and walking surfaces
- STANLEY Engineered Fastening Nelson Stud Welding Systems
- OSHA 1926.351 Arc welding equipment and electrical protection
- OSHA 1926.352 Welding fire prevention
- OSHA 1926.353 Welding ventilation and protection
Original instructional scenario with planned controls. Primary references support hazard planning. Use actual equipment and product instructions, project design and employer requirements to establish field criteria. This example supplies no inspection findings or work authorization. Use actual equipment instructions and site requirements alongside these references. Reference review: October 9, 2026.
Developed by Todd Jerome Jenkins, MS, CSP · Edition v1.0 · October 13, 2026
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