Welding, soldering, brazing, grinding and certain cutting activities, known as hot work, create risks to those doing the work and those in the area where the work is being done. Additionally fires started from hot work, including from smoldering embers, can result in catastrophic property losses.

Members who have employees, vendors or contractors performing hot work should review their procedures for hot work and align them with the noted best practices and standards below. Members should also ensure that procedures are being followed.

Prevent Risks

Hot work processes typically are performed in a designated area (e.g., maintenance shop/garage or detached outside area). However, when conducted in other locations, members should make additional site preparation(s) and implement controls to ensure safety and reduce fire hazards.

Hazards from hot work operations often result from combustibles contacting sparks or hot metals generated from the work.

To help prevent and reduce the risks associated with hot work operations, the following safety best practices should be observed before operations begin:

• Fuel and oxygen cylinders should be stored and handled in a safe manner.
• Inspect all equipment before use, ensuring that hoses are in good condition and are absent detectable leaks, and that all connections are tight and in proper order.
• Ensure that flashback arrestors and backflow preventers are properly installed on equipment.
• Check that equipment is properly grounded.
• Ensure that work is performed on a dry surface with clear access to the emergency switch or emergency disconnect at the circuit.
• Check the work area for flammable or volatile substances. Do not conduct hot work on tanks, drums or barrels until all flammable and/or toxic substances and residues are completely cleaned and removed.
• Clear all combustibles within a 35-foot radius of the hot work area (including above and below) to prevent traveling of sparks and molten metals. These can cause smolder and/or fire to ignite. If clearance is not plausible, consider use and placement of a fire-retardant blanket or other means of protection around the hot work area.
• At least one fire extinguisher with a minimum rating of 2-A:20-B:C must be readily accessible within 30 feet of any hot work location.*

Ventilation, PPE Requirements

All hot work processes produce inhalation hazards. Special attention should be given to ensuring that proper ventilation and personal protective equipment (PPE) is provided when working with galvanized metals, stainless steel and coated materials that could contain cadmium, chromium or other hazardous chemicals.

• Inspect ventilation periodically to ensure proper air flow.
• Air filters should be inspected, cleaned and/or replaced on a regular and scheduled basis.
• Flexible venting tubes should be checked for cracks or tears.
• Suitable PPE should be available, kept in good condition and worn. This may include respiratory, hearing, vision and skin protection. Additionally, loose clothing, jewelry and hair should be controlled before starting hot work. Note: If respiratory PPE is required, a written program must be in place.
• Eye protection should be worn by anyone who is near the work area, even if individuals are not performing hot work operations. All others should maintain distance with a light screen provided or proper eye wear required to be worn.

Hot Work Permit Program

If hot work activities are performed outside of a properly designated area, such as on a building’s roof or in a mechanical room, a written hot work permit program should be established and maintained regardless of the hot work operations being performed by employees or contractors. The program is to formalize best practices and outline required procedures to begin hot work.

A permit includes an inspection of the work area by a permit-authorizing individual prior to beginning hot work operations. It also includes a fire watch signature by an authorized individual tasked with watching the area for potential fire hazard(s) and inspecting the work area after the work is completed.

The individual providing the fire watch signature must be:

• Trained on the use of a portable fire extinguisher and have fire-extinguishing equipment readily accessible.
• Able to view the entire area. More fire watchers may be necessary if a potential for sparks or other items to fall vertically or leave the work-area exists.
• Able to maintain watch of the hot work area for a minimum of 60 minutes directly following the conclusion of the hot work operations.
• The hot work operator conspicuously displays this permit throughout the operation area with required visible hazard identification/warning signs displayed when the hot work area is accessible to persons other than the operator of the hot works equipment. Hazard identification should say something to the effect of “Caution hot work in progress. Stay clear.”

Learn More

Further safety rules and regulations regarding hot work are primarily found in OSHA Standard 29 CFR 1910.252, Welding, Cutting and Brazing; and the Minnesota State Fire Code.