Hot work operations, such as welding, cutting, grinding, and brazing, introduce significant fire and explosion hazards, especially when flammable materials are present [1]. A comprehensive risk assessment should address these hazards through a combination of preventive and protective measures.

Hazards Identification:

• Fire and Explosion: Hot work can ignite flammable materials in the vicinity, including gases, liquids, and dusts [1]. Vapors can flow along surfaces to distant ignition sources and flash back [1]. Heat may build pressure, rupturing closed containers, spreading fire and increasing risk of burns and injuries [1]. Some materials may react with strong oxidizing agents and should not be stored near such materials [2].
• Exposure to Hazardous Substances: Hot work can generate fumes and gases that are harmful to breathe 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 20. Some materials contain silica sand which is a suspected human carcinogen that may cause lung cancer and pulmonary fibrosis 6, 8, 9, 10, 11, 13, 15, 16, 18, 20.
• Burns: Direct contact with hot materials or sparks can cause severe burns.
• Eye Injuries: Flying sparks and debris can cause eye injuries.

Risk Assessment:

The severity of these hazards can range from minor burns to catastrophic fires or explosions, depending on the specific circumstances. The likelihood of these events depends on the control measures in place and the level of worker training and awareness.

Control Measures:

1. Elimination/Substitution:
   • Whenever possible, eliminate the need for hot work by using alternative methods such as cold cutting or mechanical fastening.
   • Substitute hazardous materials with less flammable or toxic alternatives.
2. Engineering Controls:
   • Ventilation: Use local exhaust ventilation to remove fumes and gases from the work area 6, 7, 8, 9, 10, 11, 13, 15, 16, 18, 20.
   • Fire Prevention: Ensure fire-resistant materials are used whenever possible. Use a non-combustible material like vermiculite, sand or earth to soak up the product and place into a container for later disposal [1].
   • Equipment Safety: Use equipment that is designed for hot work and is in good working condition.
3. Administrative Controls:
   • Hot Work Permit: Implement a hot work permit system to ensure that all necessary precautions are taken before hot work begins.
   • Training: Provide comprehensive training to workers on the hazards of hot work and the control measures in place.
   • Fire Watch: Assign a fire watch to monitor the work area for any signs of fire and to take immediate action if a fire occurs.
   • Housekeeping: Keep the work area clean and free of combustible materials.
   • Emergency Procedures: Develop and communicate emergency procedures in case of fire or other incidents.
4. Personal Protective Equipment (PPE):
   • Eye Protection: Wear safety goggles or safety glasses with side shields to protect against flying sparks and debris 2, 3.
   • Skin Protection: Wear appropriate impermeable gloves and protective clothing as necessary to prevent skin contact [1]. Cotton or leather gloves are recommended when handling [3].
   • Respiratory Protection: Use a properly fitted, air-purifying or air-fed respirator complying with an approved standard if a risk assessment indicates this is necessary [1].

Monitoring and Review:

• Regularly inspect hot work equipment to ensure it is in good working condition.
• Monitor the work area for any signs of fire hazards.
• Review the risk assessment and control measures periodically, or whenever there are changes in the work process or environment.

By implementing these control measures and maintaining a strong safety culture, the risks associated with hot work operations can be significantly reduced.