Hot Work Operations Risk Assessment

Assessment Date: [DATE]

Assessor: [ASSESSOR NAME]

Department/Area: [DEPARTMENT/AREA]

Review Date: [REVIEW DATE]

1. Assessment Scope

This risk assessment covers all hot work operations, including welding, cutting, grinding, soldering, and brazing, performed within the facility. It includes activities conducted by employees, contractors, and temporary workers. The scope encompasses hazard identification, risk evaluation, control measure implementation, and emergency response planning related to hot work. Excluded are hot work activities performed outside of company property or in areas not under direct company control.

2. Risk Assessment Methodology

This risk assessment employs a qualitative risk assessment method using a 5x5 risk matrix to determine risk levels. The matrix considers likelihood (Rare, Unlikely, Possible, Likely, Almost Certain) and severity (Negligible, Minor, Moderate, Major, Catastrophic) to assign a risk rating (Low, Medium, High, Extreme). Control measures are selected based on the hierarchy of controls (Elimination, Substitution, Engineering, Administrative, PPE). Residual risk is assessed after implementing controls to ensure adequate risk reduction. [3]

3. Risk Matrix Reference

The following matrix is used to evaluate risk levels based on likelihood and severity:

		Likelihood
Rare	Unlikely	Possible	Likely	Almost Certain
Severity	Catastrophic	Low	Medium	High	Extreme	Extreme
Major	Low	Medium	High	High	Extreme
Moderate	Low	Low	Medium	High	High
Minor	Low	Low	Low	Medium	High
Negligible	Low	Low	Low	Low	Medium

4. Hazard Identification and Risk Evaluation

1. Fire or explosion due to ignition of flammable or combustible materials by sparks or heat from hot work.

Potential Consequences: Severe burns, property damage, loss of life [2] [2]

Affected Persons: Workers, contractors, visitors

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Eliminate hot work by using alternative methods such as mechanical bolting or hydraulic shears.
• Substitute flammable materials with non-flammable alternatives where possible.
• Use welding blankets or screens to contain sparks and heat.
• Implement a hot work permit system to ensure proper authorization and safety checks.
• Provide fire-resistant clothing, gloves, and eye protection.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

2. Exposure to harmful fumes and gases produced during welding or cutting.

Potential Consequences: Respiratory irritation, occupational asthma, metal fume fever, long-term respiratory diseases

Affected Persons: Workers, contractors

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Ensure proper ventilation to remove fumes and gases.
• Use respiratory protection (e.g., respirators) when ventilation is inadequate.
• Monitor air quality to ensure exposure limits are not exceeded.
• Provide training on the hazards of welding fumes and gases.
• Implement engineering controls such as local exhaust ventilation.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

3. Electric shock from faulty welding equipment or improper grounding.

Potential Consequences: Electrocution, burns, cardiac arrest

Affected Persons: Workers, contractors

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	Medium

Control Measures

• Use proper grounding techniques to prevent electric shock.
• Regularly inspect welding equipment for damage or defects.
• Ensure equipment is properly maintained and repaired by qualified personnel.
• Provide insulated gloves and clothing.
• Implement lockout/tagout procedures for equipment maintenance.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

4. Eye injuries due to arc flash or flying sparks.

Potential Consequences: Corneal burns, vision impairment, blindness

Affected Persons: Workers, contractors, bystanders

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Use welding screens or barriers to protect others from arc flash and sparks.
• Wear appropriate eye protection (welding helmets with proper lens shade).
• Ensure bystanders are at a safe distance from hot work operations.
• Provide signage to warn of potential eye hazards.
• Use proper ventilation to reduce fumes and gases.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

5. Musculoskeletal injuries due to heavy lifting, awkward postures, or repetitive motions.

Potential Consequences: Sprains, strains, back injuries, carpal tunnel syndrome

Affected Persons: Workers, contractors

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Provide training on proper lifting techniques.
• Use mechanical aids (e.g., forklifts, cranes) to move heavy materials.
• Ensure adequate workspace to prevent awkward postures.
• Implement job rotation to reduce repetitive motions.
• Provide ergonomic assessments of work tasks.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

6. Slips, trips, and falls due to obstructions, spills, or uneven surfaces.

Potential Consequences: Bruises, sprains, fractures

Affected Persons: Workers, contractors

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

Control Measures

• Regularly inspect work areas for slip, trip, and fall hazards.
• Maintain clear and unobstructed walkways.
• Provide appropriate footwear with good traction.
• Clean up spills immediately.
• Use non-slip coatings on floors.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Negligible	Low

5. General Control Measures

• Implement a hot work permit system to authorize and control hot work activities.

The permit should specify the location, time, duration, and required safety precautions. [2]

• Ensure proper ventilation in areas where hot work is performed to prevent the accumulation of fumes and gases.

Use local exhaust ventilation or general ventilation systems to maintain air quality. [4]

• Regularly inspect and maintain all equipment used for hot work to ensure it is in safe operating condition.

Follow manufacturer's recommendations for inspection and maintenance schedules.

• Provide appropriate personal protective equipment (PPE) to all personnel involved in or near hot work operations.

PPE should include, but not be limited to, eye protection, face shields, gloves, and flame-resistant clothing. [4]

• Implement a fire watch program to monitor the hot work area for potential fire hazards during and after hot work operations.

Fire watch personnel should be trained in fire prevention and the use of fire extinguishers. [4]

6. Emergency Preparedness

• Ensure readily available and accessible fire extinguishers appropriate for the types of fires that could occur during hot work.
• Establish and communicate emergency evacuation procedures, including clear escape routes and assembly points.
• Train personnel on emergency shutdown procedures for equipment and processes in the hot work area.
• Maintain a fully stocked first aid kit in the vicinity of hot work operations.
• Conduct regular fire drills to ensure personnel are familiar with emergency procedures.

7. Training Requirements

• Welding Equipment Safety: Training on the safe use of welding equipment, including setup, operation, and maintenance. [4]
• Respiratory Protection: Training on the proper selection, use, and maintenance of respiratory protection equipment. [4]
• Fire Safety: Training on fire prevention and the use of fire extinguishers. [1]
• Hot Work Permit System: Training on the requirements of the hot work permit system and the responsibilities of all parties involved.
• Emergency Response: Training on emergency procedures, including evacuation routes, assembly points, and first aid.

8. Monitoring and Review

Review Frequency: Annually, or after any incident involving hot work

Monitoring Type	Frequency	Responsible Party	Description
Regular Inspection	Weekly	Safety Officer	Regular inspections of hot work areas to ensure compliance with safety procedures and permit requirements.
Performance Indicator	Monthly	Industrial Hygienist	Air quality monitoring to assess exposure levels to welding fumes and gases.
Audit	Quarterly	Safety Manager	Review of incident reports related to hot work to identify trends and areas for improvement.
Regular Inspection	Monthly	Maintenance Supervisor	Equipment inspections and maintenance records review.

9. Special Circumstances

• Hot work performed in confined spaces requires additional precautions, including atmospheric testing, ventilation, and rescue planning.
• Hot work conducted outdoors may be affected by weather conditions such as wind or rain, requiring additional controls to prevent fire hazards or exposure to the elements.
• Hot work performed at night requires adequate lighting to ensure visibility and prevent accidents.

Approval and Sign-off

This risk assessment has been reviewed and approved by:

Assessor: _________________________ Date: __________

Manager/Supervisor: _________________________ Date: __________

Safety Representative: _________________________ Date: __________

This risk assessment must be reviewed annually, or after any incident involving hot work or when significant changes occur.

Safety powered by SALUS