Welding FLHA template for Canadian worksites

A welding field-level hazard assessment (FLHA) records the hazards and controls for the exact weld, work area and shift. It should tell the crew which metal and coating are involved, where fumes and sparks will travel, how the area is ventilated, who might be exposed, and what change will stop the work. Use the blank form below with the employer's formal hazard assessment, welding procedure, exposure-control plan and any required hot-work or confined-space permit. A completed FLHA does not authorise welding in an unsafe atmosphere or substitute for competent industrial-hygiene advice.

The process matters. Arc welding, oxyfuel welding, cutting and brazing create different fumes, gases, radiation, electrical and fire exposures. CCOHS's welding overview lists these hazards and emphasises risk assessment, engineering controls and appropriate protective equipment. Canadian workplaces are regulated through the applicable provincial, territorial or federal system and site rules. Do not copy a fire-watch duration, exposure limit or ventilation setting from another jurisdiction into this card; have the competent person check the law and current site procedure.

Work and material identification

Do not leave the material field as “steel” when the workpiece is painted, plated, contaminated or joined to another material. Surface treatments can change the emission profile. CCOHS's fumes-and-gases guidance describes how coatings, solvents and the process can generate different contaminants; it recommends assessment, appropriate ventilation and controls. If the composition is unknown, identify it before heating or cutting. An old permit for bare metal does not automatically cover coated repair work.

Workface check before arc or flame

The entry should show that a control exists at the workface. “Extractor running with hood positioned beside joint and airflow verified under procedure” is useful. “Ventilation yes” is not. The hood can become ineffective as a welder moves around a large workpiece. Workers outside the screen may be exposed to the arc, fumes or sparks. Assess their location, not only the welder's.

Fire and explosion gate

Welding, cutting and grinding can ignite materials on the visible side of a wall and in concealed cavities or on the opposite side. CCOHS's hot-work guidance explains that a permit is only one part of a hot-work management programme. Consider whether the task can be moved to a designated safe area or performed without an ignition source. If not, verify the permit, removal or protection of combustibles, isolation of flammable atmospheres, fire equipment and named fire-watch arrangements. A worker should not decide to weld on a vessel, line or tank because it looks empty. The competent owner must verify cleaning, isolation, atmospheric testing and the approved procedure.

Fume and gas gate

Document the metal, consumable, coating and work geometry used in the exposure assessment. Welding fume can contain a mixture of metal and process contaminants; shielding gases and thermal breakdown products can also create hazards. CCOHS describes the source and control of welding fumes and gases. Put extraction near the plume and keep it effective as the task moves. If the work is indoors, in a pit or in another restricted space, check oxygen displacement and the applicable atmospheric programme. Respiratory equipment, if required, must be selected within the employer's competent programme; do not use a generic mask as a substitute for needed engineering control. Record sampling or reassessment where the material or process changes.

Electrical, gas and radiation gate

Inspect welding leads, clamps, cables, holders and the return path; identify the correct isolation for equipment service. Wet or conductive areas can increase shock risk. For oxyfuel work, secure cylinders, check hoses and regulators and follow the approved leak-test and shut-down method. Protect others from ultraviolet radiation and flying particles with suitable screens and exclusion. Verify that the helmet shade, gloves and clothing are suited to the task. The FLHA should not substitute a guess at the correct equipment rating or PPE specification: use the applicable procedure, manufacturer's instructions and competent selection.

Step-by-step hazard and control record

Complete the table for the actual sequence. A small repair in a populated workshop may create an exposure to people at adjacent benches. A weld in a tank may trigger a confined-space process that is far more consequential than a routine workshop weld. A new paint layer discovered during preparation may change fume and fire controls. Update the underlying assessment and permits when the change is outside the approved scope.

Stop-work and release log

Record the time, worker who identified the problem, people exposed, notifications, revised plan or permit, installed control, verifier and release decision. A fire watch should continue for the period required by the site procedure and permit; this template does not invent a universal duration. Nobody should sign the task back on until the hazard and its control have been understood by affected workers.

Crew discussion and example

Example: A welder is assigned to repair a painted steel guard in a maintenance bay. The planned assessment covers a cleaned section of bare metal. On arrival, the worker finds a fresh coating extending over the weld area and a nearby contractor using solvent. The FLHA marks the work HOLD. The supervisor identifies the coating and solvent, relocates or controls the neighbouring work, reviews the fume/extraction and fire controls, and updates the hot-work authorisation. Only after the controls are verified and both crews briefed does welding resume. A note saying “wear a respirator” would not resolve the fire or exposure uncertainty.

Existing owner, links and Complys boundary

The live Canadian hazard-assessment guide owns the general method, while the Canadian tools directory is an observed broad entry point. This proposed URL owns the narrower blank welding workface card with material, plume, fire, permit and bystander fields. It must not duplicate a full welding safety manual or any unpublished owner; verify the current repository before release. The manifest's /ca/hazard-assessment-software money route has not been confirmed live. Verify exact destination and implemented features before linking. A safe CTA is: Ask Complys how welding hazard records and corrective actions can be organised for your team. Do not claim software measures exposure, approves hot work or selects respiratory equipment.

Source, claim, owner, product and writer-side QA register — 5 October 2026

Terminal writer-side disposition: READY. No Complys website or repository content was modified.