Hot Work Safety Checklist

A valid hot work permit is available for the task and location.

The permit is displayed or immediately available at the work location.

Required permit approvals and signatures are complete.

The task-specific risk assessment or JSA has been reviewed.

A task-specific toolbox talk has been completed and recorded.

Simultaneous operations and nearby activities have been assessed.

Personnel performing the work are trained, competent and authorized.

A competent supervisor is assigned and available.

Workers understand the emergency alarm, escape route and assembly point.

The need for atmospheric testing has been formally assessed.

The gas detector is suitable, within calibration and function-tested.

Oxygen concentration is within the site-approved safe range.

Flammable gas or vapour concentration is below the permitted limit.

Toxic gases relevant to the area have been tested where required.

Continuous or periodic atmospheric monitoring is arranged where conditions may change.

Combustible and flammable materials have been removed or effectively protected.

Suitable fire extinguishing equipment is immediately available.

A trained fire watch has been assigned where required.

The fire watch understands alarm methods, extinguisher use and stop-work authority.

Openings, penetrations, drains and gaps are protected from sparks and slag.

Spark and slag containment is effective for the work configuration.

Fire detection or suppression systems affected by the task are properly managed.

Post-work fire monitoring duration has been defined.

Hot work equipment has passed the required pre-use inspection.

Electrical cables, plugs, electrode holders and connections are undamaged.

The welding return connection is secure and positioned appropriately.

Gas cylinders are upright, secured and protected from damage.

Oxygen and fuel-gas equipment is free from oil, grease and contamination.

Hoses, regulators, valves and connections are compatible and leak-free.

Required flashback arrestors and non-return valves are correctly installed.

Grinding wheels and cutting discs are suitable, undamaged and within their rated speed.

Machine guards and handles are installed and correctly positioned.

Eye and face protection is suitable for the hot work process.

Flame-resistant clothing provides adequate body coverage.

Gloves are suitable for heat, sparks and the task being performed.

Safety footwear is suitable and protects against hot material.

Hearing protection is provided where noise exposure requires it.

Respiratory protection is provided where fumes or contaminants cannot be adequately controlled otherwise.

Fall protection is provided where work-at-height exposure exists.

The work area is barricaded and warning signs are displayed.

Ventilation is adequate for fumes, gases and heat generated by the task.

Lighting is sufficient for safe work and inspection.

Access and emergency escape routes are clear.

Housekeeping is acceptable and trip hazards are controlled.

Weather conditions are suitable for the work.

Screens or barriers protect nearby personnel from arc radiation and flying particles.

Permit conditions and control measures remain effective throughout the work.

The fire watch remains in position and continuously observes the risk area.

Workers continue to use required PPE correctly.

No gas leak, unexpected odour, alarm or process release is present.

Hot slag, sparks and workpieces remain contained and controlled.

The hot work equipment has been safely shut down and isolated.

The work area and all potentially affected levels have been inspected.

The required post-work fire-watch period has been completed and recorded.

Hot materials, electrode stubs, slag and waste have been safely removed.

Temporary barriers, covers and fire protection controls are removed only when safe.

The permit has been formally closed by the authorized persons.