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, conducted within the facility. It includes activities performed by employees, contractors, and visitors. The assessment considers all phases of hot work, from preparation to completion, including potential fire hazards, exposure to fumes and gases, and physical injuries. Excluded from this assessment are hot work operations conducted outside the facility's boundaries and any work on energized electrical equipment (which requires a separate Lockout/Tagout procedure).

2. Risk Assessment Methodology

This risk assessment employs a qualitative 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). Hazards are identified through workplace inspections, review of incident reports, and consultation with workers. Control measures are selected based on the hierarchy of controls (Elimination, Substitution, Engineering, Administrative, PPE). The residual risk is then assessed to ensure controls are effective.

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	Low	Medium	High	Extreme
Major	Low	Low	Medium	High	Extreme
Moderate	Low	Medium	High	Extreme	Extreme
Minor	Low	Medium	High	High	Extreme
Negligible	Low	Low	Medium	High	Extreme

4. Hazard Identification and Risk Evaluation

1. Fire hazard due to sparks and hot materials igniting flammable substances in the work area.

Potential Consequences: Fire, explosion, burns, property damage.

Affected Persons: Workers, contractors, visitors

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Eliminate the need for hot work by using alternative methods such as mechanical bolting or hydraulic shears.
• Use local exhaust ventilation to remove fumes and gases at the source.
• Provide fire-resistant blankets and screens to contain sparks and slag.
• Implement a hot work permit system to ensure proper authorization and preparation.
• Require the use of appropriate PPE, including respirators, welding helmets, and fire-resistant clothing.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

2. Exposure to welding fumes and gases, such as metal oxides, ozone, and nitrogen oxides.

Potential Consequences: Respiratory irritation, metal fume fever, chronic lung disease.

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Substitute welding rods with lower fume emissions.
• Use welding techniques that minimize fume generation.
• Ensure adequate general ventilation in the work area.
• Provide workers with properly fitted respirators.
• Implement a respiratory protection program, including training and fit testing.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

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

Potential Consequences: Electric shock, burns, cardiac arrest.

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

Control Measures

• Use properly grounded welding equipment.
• Inspect welding cables for damage before each use.
• Ensure the work area is dry and free of standing water.
• Provide insulated gloves and footwear.
• Implement lockout/tagout procedures for electrical equipment.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Minor	Low

4. Exposure to ultraviolet (UV) radiation from welding arcs.

Potential Consequences: Eye damage (arc eye), skin burns, increased risk of skin cancer.

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Provide welding helmets with appropriate shade lenses.
• Use screens or barriers to protect others from arc flash.
• Ensure proper ventilation to remove ozone.
• Provide workers with UV-protective clothing.
• Limit exposure time to UV radiation.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

5. Musculoskeletal injuries from repetitive motions, awkward postures, and heavy lifting.

Potential Consequences: Sprains, strains, carpal tunnel syndrome.

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Use ergonomic tools and equipment to reduce strain.
• Provide training on proper lifting techniques.
• Implement job rotation to reduce repetitive motions.
• Ensure adequate lighting in the work area.
• Provide anti-fatigue mats for workers who stand for long periods.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

5. General Control Measures

• Implement a hot work permit system that requires authorization before any hot work begins. The permit should specify the hazards, controls, and required PPE.

The permit should be completed by a competent person and reviewed by a supervisor.

• Ensure that all workers involved in hot work operations receive adequate training on the hazards, controls, and safe work practices.

Training should include hands-on practice and regular refresher courses.

• Conduct regular inspections of hot work areas to ensure that controls are in place and effective.

Inspections should be documented and any deficiencies corrected promptly.

• Maintain a fire watch during and after hot work operations to monitor for any signs of fire.

The fire watch should be trained in fire prevention and suppression and equipped with a fire extinguisher.

• Provide and require the use of appropriate personal protective equipment (PPE), including welding helmets, respirators, gloves, and fire-resistant clothing.

PPE should be properly fitted and maintained.

6. Emergency Preparedness

• Ensure that fire extinguishers are readily available and appropriate for the types of fires that could occur.
• Establish an emergency evacuation plan that includes clear escape routes and assembly points.
• Provide training on emergency procedures, including fire suppression and first aid.
• Maintain a first aid kit and ensure that trained first aid personnel are available.
• Establish a communication system for reporting emergencies.

7. Training Requirements

• Respiratory Protection Training: Workers must be trained on the proper use, maintenance, and limitations of respirators. Training should include fit testing and instruction on how to inspect respirators for damage.
• Hot Work Safety Training: Workers must be trained on the hazards of hot work, including fire hazards, fume exposure, and electrical hazards. Training should include the proper use of fire extinguishers and other safety equipment.
• Personal Protective Equipment (PPE) Training: Workers must be trained on the proper selection, use, and maintenance of welding helmets, gloves, and other PPE.
• Ergonomics and Safe Lifting Training: Workers must be trained on the proper techniques for lifting and handling heavy materials to prevent musculoskeletal injuries.
• Hot Work Permit Training: Workers must be trained on the procedures for obtaining a hot work permit and the requirements for preparing a hot work area.

8. Monitoring and Review

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

Monitoring Type	Frequency	Responsible Party	Description
Regular Inspection	Monthly	Maintenance Department	Regularly inspect welding equipment for damage and ensure that it is properly grounded.
Performance Indicator	Annually	Occupational Health and Safety Department	Monitor worker exposure to welding fumes and gases using air sampling techniques.
Audit	Annually	Occupational Health and Safety Department	Conduct regular audits of hot work operations to ensure compliance with safety procedures.
Incident Review	Quarterly	Occupational Health and Safety Committee	Review incident reports to identify trends and areas for improvement.
Observation	Ongoing	Supervisors	Monitor the effectiveness of control measures by observing worker behavior and gathering feedback.

9. Special Circumstances

• Hot work performed in confined spaces requires additional precautions, such as continuous air monitoring and ventilation.
• Hot work performed at heights requires fall protection measures, such as safety harnesses and guardrails.
• Hot work performed in wet or damp conditions requires extra precautions to prevent electric shock.
• Hot work performed near flammable materials requires additional fire prevention measures, such as fire blankets and extinguishers.
• Lone workers performing hot work should have a system in place for regular check-ins and emergency communication.

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.

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