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 conducted within the facility, including welding, cutting, grinding, soldering, and any other activities that generate sparks, heat, or open flames. The assessment includes all areas where hot work may be performed, including designated hot work areas, maintenance shops, and other locations as needed. Excluded from this assessment are hot work operations performed by external contractors, who are responsible for their own risk assessments.

2. Risk Assessment Methodology

This risk assessment follows a qualitative risk assessment methodology using a 5x5 risk matrix to determine risk levels. The likelihood of occurrence is rated as Rare, Unlikely, Possible, Likely, or Almost Certain. The severity of potential consequences is rated as Negligible, Minor, Moderate, Major, or Catastrophic. The risk rating is then determined by combining the likelihood and severity ratings, resulting in a risk level of Low, Medium, High, or Extreme. Control measures are identified based on the hierarchy of controls (Elimination, Substitution, Engineering Controls, Administrative Controls, and PPE) to reduce risks to acceptable levels.

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

4. Hazard Identification and Risk Evaluation

1. Fire hazards due to sparks, heat, and open flames igniting flammable or combustible materials in the work area.

Potential Consequences: Fires, explosions, burns, and property damage.

Affected Persons: Workers, fire watch personnel, and nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Major	High

Control Measures

• Eliminate the need for hot work by using alternative methods such as mechanical bolting or hydraulic shears.
• Use welding blankets or curtains to contain sparks and heat.
• Ensure proper ventilation to remove fumes and gases.
• Implement a fire watch with trained personnel and appropriate fire suppression equipment.
• Use appropriate PPE, including fire-resistant clothing, gloves, and eye protection.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

2. Exposure to welding fumes and gases, which can cause respiratory irritation, metal fume fever, and long-term health effects.

Potential Consequences: Respiratory illnesses, metal fume fever, and long-term health problems.

Affected Persons: Workers and nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Ensure proper ventilation to remove welding fumes and gases.
• Use local exhaust ventilation systems.
• Provide respirators when ventilation is inadequate.
• Monitor air quality to ensure exposure limits are not exceeded.
• Implement administrative controls to limit exposure duration.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

3. Electrical shock hazards from faulty equipment or improper grounding.

Potential Consequences: Electrical shock, burns, and electrocution.

Affected Persons: Workers and nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

Control Measures

• Use properly insulated welding cables and equipment.
• Ensure equipment is regularly inspected and maintained.
• Provide GFCI protection for electrical outlets.
• Keep work areas dry and free of standing water.
• Use appropriate PPE, including insulated gloves and footwear.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Minor	Low

4. Exposure to ultraviolet (UV) radiation from welding arcs, which can cause burns to the skin and eyes (arc eye).

Potential Consequences: Skin burns, arc eye, and long-term vision damage.

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Use welding screens or curtains to protect others from arc flash.
• Provide appropriate eye protection (welding helmets with proper lens shade).
• Ensure proper ventilation to remove ozone and other gases produced by UV radiation.
• Wear appropriate clothing to cover exposed skin.
• Limit exposure duration.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

5. Hazards associated with compressed gas cylinders, including explosions, leaks, and projectiles if cylinders are damaged or mishandled.

Potential Consequences: Explosions, projectile hazards, and asphyxiation.

Affected Persons: Workers and nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

Control Measures

• Ensure proper storage and handling of compressed gas cylinders.
• Use regulators and hoses in good condition.
• Secure cylinders to prevent tipping or falling.
• Inspect cylinders for damage before use.
• Provide training on the safe use of compressed gases.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Minor	Low

6. Ergonomic hazards from repetitive motions, awkward postures, and heavy lifting during hot work operations.

Potential Consequences: Musculoskeletal disorders, strains, and sprains.

Affected Persons: Workers and nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Provide ergonomic assessments of work tasks.
• Use adjustable work platforms and equipment.
• Train workers on proper lifting techniques and posture.
• Implement administrative controls to reduce repetitive motions.
• Encourage regular breaks and stretching exercises.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

7. Inadequate fire prevention measures leading to the ignition of combustible materials.

Potential Consequences: Rapid fire spread, property damage, and potential injuries or fatalities.

Affected Persons: Workers and fire watch personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Major	High

Control Measures

• Clear the hot work area of all combustible materials within a 35-foot radius.
• Cover or shield any remaining combustible materials with fire-resistant blankets or screens.
• Ensure a fire watch is present during and after hot work operations.
• Provide fire extinguishers and other fire suppression equipment.
• Train workers and fire watch personnel on fire prevention and suppression techniques.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

5. General Control Measures

• Implement a comprehensive hot work permit system to authorize and control all hot work activities, ensuring proper hazard assessment and control measures are in place before work begins.

The permit should detail the work to be done, the hazards involved, and the control measures required.

• Maintain clear communication channels between workers, supervisors, and fire watch personnel to ensure everyone is aware of the hot work being performed and any potential hazards.

Use radios or other communication devices to maintain contact.

• Ensure all workers involved in hot work operations receive comprehensive training on hot work safety, hazard identification, fire prevention, and the proper use of equipment and PPE.

Training should be documented and regularly updated.

6. Emergency Preparedness

• Ensure readily available and appropriate fire extinguishers are present in all hot work areas, inspected regularly, and personnel are trained in their proper use.
• Establish and communicate emergency evacuation procedures, including clear escape routes and assembly points, and conduct regular drills.
• Provide readily accessible fire blankets for immediate suppression of small fires or to protect personnel from flames.

7. Training Requirements

• Personal Protective Equipment (PPE) Training: Workers must be trained in the proper selection, use, and maintenance of PPE, including fire-resistant clothing, gloves, eye protection, and respiratory protection.
• Fire Prevention Training: Training should cover the identification of flammable and combustible materials, proper storage techniques, and the importance of maintaining a clean and organized work area.
• Fire Suppression Training: Workers must be trained on the proper use of fire extinguishers, fire blankets, and other fire suppression equipment.

8. Monitoring and Review

Review Frequency: Annually, and after any incident or significant change in hot work procedures or equipment

Monitoring Type	Frequency	Responsible Party	Description
Regular Inspection	Weekly	Safety Department	Regular inspections of hot work areas to ensure compliance with safety procedures and permit requirements.
Performance Indicator	Monthly	Occupational Health	Air quality monitoring to assess worker exposure to welding fumes and gases.
Audit	After each incident	Safety Manager	Review of incident reports and near-miss investigations related to hot work operations.

9. Special Circumstances

• Hot work performed in confined spaces requires additional precautions, including atmospheric testing, ventilation, and rescue planning.
• Adverse weather conditions, such as high winds or rain, can increase the risk of fire and electrical hazards during outdoor hot work.
• Hot work conducted 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, and after any incident or significant change in hot work procedures or equipment or when significant changes occur.

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