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Hot Work Safety

Essential guidance for welding, cutting, grinding and other operations that can generate heat, sparks or open flames.

OSHA8 min readHigh Risk

Overview

Hot work can cause fire, explosion, burns and harmful fume exposure. Work should begin only after the permit, area inspection, isolation, fire-prevention controls and emergency arrangements have been verified.

Main Hazards

  • • Fire and explosion
  • • Flying sparks and molten metal
  • • Hot surfaces and burns
  • • Toxic welding fumes and gases
  • • Oxygen enrichment or fuel-gas leakage
  • • Ignition of hidden combustible materials
  • • Arc radiation and eye injury
  • • Fire spreading to adjacent levels or areas

Required PPE

  • ✓Safety glasses with side protection
  • ✓Suitable welding helmet or face shield
  • ✓Flame-resistant clothing
  • ✓Heat-resistant welding gloves
  • ✓Safety footwear
  • ✓Hearing protection where required
  • ✓Respiratory protection where ventilation is insufficient

Essential Controls

  1. 1Obtain and display an approved hot-work permit before starting.
  2. 2Inspect the work area and remove or protect combustible materials.
  3. 3Test the atmosphere where flammable gases or vapours may be present.
  4. 4Isolate nearby process equipment, lines and energy sources as required.
  5. 5Provide suitable fire extinguishers and fire blankets at the work area.
  6. 6Assign a competent fire watch with no conflicting duties.
  7. 7Control sparks, slag and hot material from reaching lower or adjacent areas.
  8. 8Inspect welding leads, hoses, regulators and equipment before use.
  9. 9Maintain adequate ventilation and control welding fumes.
  10. 10Continue fire watch and inspect the area after work is completed.

Common Mistakes

  • ×Starting work before the permit is approved
  • ×Using a fire watch who is distracted by other duties
  • ×Leaving combustible materials below or behind the work area
  • ×Using damaged welding leads, hoses or regulators
  • ×Failing to test the atmosphere where required
  • ×Allowing oxygen cylinders or hoses to leak into enclosed areas
  • ×Stopping fire watch immediately when welding ends
  • ×Using unsuitable screens or blankets that do not contain sparks

Pre-work Checklist

  • ✓Hot-work permit is approved and available
  • ✓The work area and adjacent levels have been inspected
  • ✓Combustible materials have been removed or protected
  • ✓Gas testing has been completed where required
  • ✓Fire extinguishers and fire blankets are ready
  • ✓A competent fire watch has been assigned
  • ✓Welding equipment, leads and hoses are in good condition
  • ✓Ventilation is adequate
  • ✓The area below has been barricaded where necessary
  • ✓Post-work fire-watch duration has been confirmed

Emergency Response

Stop work immediately if fire, gas release, equipment failure or unsafe conditions develop. Raise the alarm, isolate energy or gas supplies when safe, evacuate the area and use firefighting equipment only if trained and conditions allow.

OSHA References

OSHA 1910.252OSHA 1926 Subpart JOSHA 1926.352NFPA 51B

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