Hot Work Operations

Document Number: [SWP-NUMBER]

Revision Date: [DATE]

Next Review Date: [NEXT REVIEW DATE]

Department: [DEPARTMENT NAME]

1. Scope

This safe work procedure applies to temporary hot work operations including welding, cutting, grinding, brazing, soldering, and related spark- or flame-producing tasks performed in workshops, construction areas, maintenance zones, process areas, and other locations where combustible or flammable materials may be present. It covers planning, permit-to-work controls, hazard identification, isolation and lockout/tagout, gas testing, ventilation, combustible materials control, fire watch, PPE, emergency response, and post-work inspection. The procedure is intended for routine and non-routine hot work performed outside designated hot work areas, and for designated areas where additional controls are still required. It does not replace task-specific engineering controls, confined space procedures, process safety management requirements, or site-specific emergency plans. Hot work should be avoided where feasible by using alternative methods that do not introduce ignition sources, and it must not proceed where explosive atmospheres, uncontrolled flammable vapours, or other intolerable conditions cannot be eliminated or effectively controlled.

2. Definitions

Hot Work Any temporary operation that produces open flames, heat, sparks, or radiant energy capable of igniting nearby combustible or flammable materials. Typical examples include welding, cutting, brazing, grinding, soldering, and torch work. Fire Watch A trained person assigned solely to observe hot work and surrounding areas for signs of fire, smouldering, or unsafe changes in conditions, and to initiate alarm and suppression actions if needed. The fire watch must not perform the hot work itself or other distracting duties. Lower Explosive Limit (LEL) The minimum concentration of a flammable gas or vapour in air that can ignite. Hot work must not begin or continue when atmospheric conditions indicate an unsafe combustible gas concentration. Lockout/Tagout (LOTO) A formal energy isolation process used to de-energize, lock, tag, block, blank, bleed, or otherwise secure equipment and systems so they cannot release hazardous energy during hot work. Permit to Work A written authorization system used to verify that hazards have been assessed and required controls are in place before hot work begins. The permit documents the work scope, precautions, approvals, fire watch, and monitoring requirements.

3. Responsibilities

3.1 Supervisors

• Authorize hot work only after confirming that the task cannot be eliminated or substituted with a safer method, and that the work area has been assessed for fire, explosion, toxic exposure, and energy-isolation hazards.
• Ensure a valid hot work permit is issued, posted, understood by the crew, and retained according to site procedure. Verify that permit conditions remain valid throughout the job and that work stops if conditions change.
• Confirm that equipment, hoses, cables, regulators, ventilation, fire extinguishers, gas monitors, and other controls are inspected and suitable for use before work starts.
• Ensure combustible materials are removed, shielded, wetted down, or otherwise protected; openings and penetrations are sealed; and adjacent operations are isolated from sparks, slag, and heat transfer.
• Assign a trained fire watch where required, ensure the fire watch has no conflicting duties, and verify post-work monitoring continues for the required period until the area is confirmed safe.
• Stop work immediately when unsafe conditions arise, including gas readings outside acceptable limits, ventilation failure, fire watch absence, equipment defects, or introduction of new combustibles.

3.2 Workers

• Follow the hot work permit, site rules, and this procedure at all times, and do not begin work until all required controls are in place and understood.
• Inspect tools, leads, hoses, cylinders, regulators, guards, and PPE before use, and remove defective equipment from service immediately.
• Wear the required PPE correctly, maintain housekeeping around the work area, and keep clothing free of oil, grease, solvents, and other flammable contamination.
• Maintain communication with the supervisor and fire watch, report changing conditions immediately, and stop work if sparks, fumes, heat, or gas readings indicate increased risk.
• Use ventilation, shielding, and isolation measures as instructed, and never bypass guards, interlocks, or energy-isolation devices.
• Report incidents, near misses, damaged equipment, and unsafe conditions promptly and cooperate with investigations and corrective actions.

3.3 Health and Safety Representative

• Review hot work controls, permit practices, and incident trends to verify that the program is effective and aligned with site safety requirements and applicable regulations.
• Participate in hazard assessments, inspections, and audits of hot work areas, including verification of fire protection, ventilation, gas testing, and housekeeping controls.
• Support worker training and competency verification for hot work, fire watch duties, gas monitoring, PPE selection, and emergency response.
• Assist with incident and near-miss investigations, identify root causes and systemic issues, and track corrective actions to completion.

4. Potential Hazards and Risks

5. Personal Protective Equipment (PPE)

Personal protective equipment is the last line of defense and must be selected to match the specific hot work process, the materials involved, and the surrounding hazards. PPE does not replace engineering controls, isolation, ventilation, housekeeping, or fire prevention measures.

• Welding Helmet or Face Shield with Correct Filter Lens: Wear a welding helmet or approved face shield fitted with a filter lens and cover plate suitable for the process and arc intensity. The helmet must protect the face, forehead, neck, and ears from radiant energy, sparks, and spatter. Lens shade must be selected for the specific operation, and the equipment must comply with applicable eye and face protection standards.
  • Use approved safety glasses with side shields or goggles under the helmet.
  • Replace damaged, cracked, or pitted lenses immediately.
  • Use prescription-compatible eye protection where required.
• Safety Glasses or Goggles with Side Shields: Wear impact-resistant safety glasses with side shields, or goggles where splash or fragment hazards are greater, beneath the welding helmet or face shield. This secondary protection helps prevent injury from flying metal, slag chips, grinding fragments, and wire wheel bristles that can ricochet under the primary face protection.
  • Ensure a secure fit that does not interfere with the helmet.
  • Use goggles when grinding or when fine particles may bypass open-frame glasses.
• Flame-Resistant Clothing: Wear clean, oil-free flame-resistant clothing made from leather or inherently flame-resistant material. Clothing should cover the arms and legs fully, fit properly, and avoid cuffs or loose fabric that can trap sparks. Synthetic materials that can melt onto the skin must not be worn where they could be exposed to heat or spatter.
  • Button cuffs, pockets, and collars.
  • Wear long pants over work footwear.
  • Use leather sleeves or aprons when exposure to spatter is elevated.
• Hand Protection: Wear heat-resistant welding gloves or task-appropriate gloves that provide protection from heat, sparks, sharp edges, and minor abrasion while still allowing adequate dexterity. Gloves must be dry, intact, and suitable for the process being performed.
  • Select gloves with extended cuffs for wrist and forearm protection.
  • Remove gloves from service if they are burned, torn, or contaminated with flammables.
• Foot Protection: Wear sturdy, closed-toe safety footwear with heat-resistant uppers and slip-resistant soles. Footwear should protect against falling objects, hot slag, and accidental contact with hot surfaces.
  • Use metatarsal protection where falling-object hazards exist.
  • Keep trouser legs outside or over the boot tops as appropriate to prevent spark entry.
• Hearing and Head Protection: Use hearing protection when noise levels or overhead hot work create a risk of hearing damage or spark entry into the ears. A fire-resistant cap or head covering should be worn under the helmet to reduce burn risk from falling sparks and spatter.
  • Use earplugs or earmuffs where overhead work or high noise is present.
  • Ensure head coverings are flame-resistant and fit comfortably under the helmet.

Inspect PPE before each use for cracks, burns, contamination, broken stitching, degraded elastic, damaged lenses, and poor fit. Clean and store PPE according to manufacturer instructions, keep lenses free of scratches that impair visibility, and replace any item that no longer provides reliable protection. Do not use PPE that has been contaminated with oil, grease, solvents, or other flammable substances.

6. Equipment and Tools

Hot work equipment must be suitable for the task, maintained in safe operating condition, and inspected before use to prevent leaks, electrical faults, uncontrolled sparks, and other failures that can lead to fire, explosion, or injury.

• Welding, Cutting, or Brazing Equipment: Use equipment appropriate to the process, including torches, power sources, leads, hoses, regulators, and accessories. Equipment must be compatible with the material and process, properly assembled, and protected from damage. Defective equipment must be removed from service immediately.
  • Verify correct settings and connections before energizing or lighting.
  • Keep equipment away from traffic, sharp edges, and hot surfaces.
• Gas Cylinders and Associated Controls: Use secured cylinders with correct caps, regulators, flashback protection where required, and leak-free connections. Cylinders must be stored, transported, and used upright and protected from heat, impact, and contamination.
  • Check for leaks with approved methods before use.
  • Keep oxygen and fuel gas cylinders separated and secured.
• Portable Gas Monitor: Use a calibrated gas monitor where atmospheric hazards may exist, especially in confined spaces, process areas, or locations with potential flammable vapours. The monitor must be suitable for oxygen, combustible gas, and toxic gas detection as required by the hazard assessment.
  • Perform bump tests and calibration checks per manufacturer and site requirements.
  • Document readings before, during, and after work when monitoring is required.
• Fire Extinguishers and Fire Suppression Equipment: Provide readily accessible, appropriate fire extinguishers and verify that fixed fire protection systems, hoses, and alarms are in service where applicable. Fire suppression equipment must be selected for the expected fire class and kept unobstructed.
  • Confirm extinguisher type and rating are suitable for the hazard.
  • Ensure workers and fire watch personnel know how to use the equipment.
• Ventilation Equipment and Local Exhaust: Use natural or mechanical ventilation, and local exhaust where effective, to control fumes, gases, and heat accumulation. Ventilation equipment must be positioned to remove contaminants away from workers and must not create new hazards by spreading sparks or vapours.
  • Do not use compressed gases for ventilation or cleaning.
  • Verify airflow is adequate before and during work.

Inspect all hot work tools and accessories before each shift and after any event that could damage them. Check hoses for cracks, burns, abrasion, and leaks; verify regulators and gauges function correctly; inspect cables and connectors for wear, insulation damage, and secure connections; confirm guards and shields are in place; and ensure cylinders are secured and labelled. Remove defective equipment from service, tag it out, and repair or replace it before reuse.

7. Pre-Job Requirements

7.1 Training and Competency

Training and Competency: Only trained and authorized workers may perform hot work, act as fire watch, operate gas monitors, or issue permits. Training must cover hazard recognition, permit requirements, equipment inspection, PPE use, fire prevention, ventilation, gas testing, emergency response, and stop-work authority. Supervisors must verify competency before assigning work, and refresher training must be provided when procedures, equipment, or hazards change.

7.2 Pre-Job Briefing

Pre-Job Briefing: Conduct a documented pre-job briefing before each hot work task. Review the scope of work, hazards, controls, permit conditions, emergency actions, communication methods, fire watch assignment, ventilation plan, isolation points, gas testing requirements, and stop-work triggers. Confirm that all workers understand the sequence of work and the boundaries of the hot work area.

7.3 Work Area Preparation

Work Area Preparation: Prepare the work area by removing or shielding combustibles, sealing openings, protecting adjacent surfaces, and ensuring fire protection equipment is available and operable. Inspect concealed spaces, ducts, wall cavities, floors, and lower levels where sparks or heat may travel. If combustibles cannot be removed, protect them with fire-resistant blankets, shields, or other approved barriers.

8. Safe Work Procedure Steps

1. 1. Confirm the Need for Hot Work: Verify that the task cannot be completed by a safer alternative method such as mechanical bolting, hydraulic shearing, clamped or flanged connections, or mechanical cutting. If a non-hot-work method can achieve the same result without introducing ignition sources, use that method instead. Safety notes: eliminating hot work is the preferred control because it removes the ignition source entirely.
2. 2. Obtain Authorization and Issue the Hot Work Permit: Complete the permit-to-work process before starting. The permit must identify the work location, scope, hazards, required controls, fire watch, ventilation, isolation, gas testing, and duration of validity. Post the permit at the worksite and ensure all involved personnel understand its conditions. Safety notes: do not begin work until the permit is approved and all listed precautions are in place.
3. 3. Inspect the Work Area and Identify Hazards: Conduct a thorough inspection of the immediate area and surrounding spaces, including walls, ceilings, floors, ducts, concealed voids, and lower levels. Identify combustible materials, flammable liquids, gases, dusts, oxygen sources, pressurized systems, electrical hazards, and nearby operations that could be affected by sparks or heat. Safety notes: sparks can travel significant distances and may ignite hidden combustibles long after the work is finished.
4. 4. Isolate Energy Sources and Apply Lockout/Tagout: De-energize, lock, tag, block, blank, bleed, or otherwise isolate equipment and systems that could release hazardous energy or create ignition hazards. Verify zero-energy state before work begins. Safety notes: isolation must include electrical, mechanical, hydraulic, pneumatic, thermal, and process energy sources as applicable to the task.
5. 5. Remove, Shield, or Control Combustible Materials: Remove combustible materials from the area whenever possible. If removal is not practical, cover them with fire-resistant blankets or shields and protect openings, cracks, and penetrations with approved fire-resistant materials. Safety notes: keep floors clean, remove oil and grease, and protect adjacent surfaces and lower levels from falling sparks and slag.
6. 6. Establish Ventilation and Atmospheric Controls: Provide natural or mechanical ventilation to control fumes, gases, and heat. Where atmospheric hazards may exist, test the atmosphere before work and monitor it during the task as required. Safety notes: do not use oxygen for ventilation, and stop work if ventilation becomes ineffective or gas readings move outside acceptable limits.
7. 7. Verify Equipment, Cylinders, and PPE: Inspect all tools, hoses, cables, regulators, cylinders, guards, and accessories before use. Confirm that all required PPE is available, in good condition, and worn correctly. Safety notes: remove defective equipment from service immediately and do not improvise repairs that could compromise safety.
8. 8. Assign and Brief the Fire Watch: Assign a trained fire watch whenever required by the permit or hazard assessment. The fire watch must remain focused on detecting sparks, smouldering, heat buildup, or fire, and must have immediate access to suitable fire extinguishing equipment. Safety notes: the fire watch must not perform other tasks and must remain in place during breaks and for the required post-work monitoring period.
9. 9. Perform the Hot Work Under Controlled Conditions: Carry out welding, cutting, grinding, or brazing in accordance with the approved procedure, maintaining control of sparks, slag, heat, and fumes. Keep the work area orderly, maintain communication, and stop immediately if conditions change. Safety notes: maintain awareness of nearby workers, overhead hazards, and hidden ignition sources throughout the task.
10. 10. Complete Post-Work Inspection and Close the Permit: After work is complete, inspect the area, including adjacent spaces, concealed voids, lower levels, and surfaces that may have been heated. Confirm that no smouldering, smoke, hot spots, or gas leaks remain. Return equipment to safe condition, remove waste, and close out the permit according to site procedure. Safety notes: continue fire watch and monitoring for the required period after completion, especially where sparks may have entered hidden spaces.

9. Precautions and Safety Measures

• Maintain strict housekeeping before, during, and after hot work. - Remove dust, scrap, oily rags, packaging, and other combustibles from the area. Store waste in approved containers and keep access routes clear for emergency response.
• Use a dedicated fire watch whenever sparks, slag, or heat could reach combustibles or hidden spaces. - The fire watch must be trained, attentive, and equipped with suitable extinguishing equipment. Maintain the watch during breaks and after work until the area is confirmed safe.
• Control access to the hot work area. - Barricade or sign the area as needed to keep unauthorized personnel away from sparks, fumes, and radiant energy. Coordinate with nearby work groups to prevent conflicting activities.
• Maintain continuous awareness of atmospheric conditions where required. - Use gas testing before work and continuous or periodic monitoring during work in areas with potential flammable vapours, oxygen enrichment, or toxic fumes. Stop work if alarms activate or readings become unsafe.
• Protect adjacent structures, openings, and concealed spaces from spark travel. - Seal cracks, cover penetrations, inspect ducts and voids, and use fire-resistant barriers or blankets to prevent ignition in hidden areas.

10. Emergency Procedures

10.1 General Emergency Response

If fire, explosion risk, gas alarm, smoke, uncontrolled spark spread, or injury occurs, stop work immediately, alert nearby personnel, and activate the site emergency response plan. The fire watch or nearest trained worker should use an appropriate extinguisher only if the fire is small, escape is clear, and the person is trained to do so. If the fire cannot be controlled quickly, evacuate, isolate the area if safe, and contact emergency responders. Provide first aid for burns, eye injuries, smoke inhalation, or shock as trained, and do not re-enter the area until it has been declared safe.

10.2 Specific Emergency Scenarios

• Small incipient fire caused by sparks or slag on combustibles: Stop hot work, alert the fire watch and nearby workers, and use the nearest appropriate extinguisher if trained and safe to do so. If the fire is not extinguished immediately, evacuate the area, close doors if this can be done safely, and summon emergency response. Reinspect the area for hidden smouldering after the incident is controlled.
• Gas monitor alarm or detection of flammable vapours: Stop work immediately, shut down ignition sources if safe, evacuate personnel from the affected area, and investigate the source of the vapour release. Do not resume hot work until the atmosphere is retested, the source is controlled, and the permit is revalidated.
• Burn injury, eye injury, or electric shock during hot work: Stop the task, make the area safe, and provide first aid or emergency medical assistance as required. For electric shock, isolate power before touching the victim if possible. For burns or eye injuries, flush or cool the affected area according to first aid guidance and arrange prompt medical evaluation.
• Ventilation failure or loss of atmospheric control in a confined or semi-enclosed area: Stop hot work, evacuate the area if fumes or gases cannot be controlled, and restore ventilation before resuming. Re-test the atmosphere and confirm that all permit conditions remain valid before restarting work.

10.3 Emergency Contact Information

Emergency contact information must be posted or readily available at the worksite in accordance with site emergency procedures. Workers must know how to contact site emergency response, supervision, first aid support, and external emergency services as applicable. [1] [2]

11. Incident Reporting and Investigation

Report all incidents, near misses, gas alarms, equipment failures, fire watch lapses, permit deviations, and unsafe conditions to supervision immediately and through the site incident reporting system. Preserve the scene where practical, isolate damaged equipment, and document the time, location, personnel involved, atmospheric readings, permit status, and immediate corrective actions taken. Near misses must be treated as serious learning events because they often indicate a credible fire or injury risk.

Investigate each reportable event promptly to determine direct causes, contributing factors, and root causes. Review the permit, pre-job briefing, equipment inspection records, gas test results, ventilation status, housekeeping conditions, fire watch performance, and isolation controls. Assign corrective actions, verify completion, and communicate lessons learned to affected workers and supervisors so the same failure does not recur.

Approved by: [NAME AND POSITION]

Date: [APPROVAL DATE]

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