Welding, Cutting and Hot Work

Purpose and Objective 

The Welding, Cutting, and Hot Work Program has been established to protect the safety of employees and property by establishing appropriate hot work procedures. This policy applies to all employees and all facilities. 

Definitions 

Combustible: A substance which is able to catch fire and burn easily. 

Fire Watch: An employee assigned to observe the area in which hot work is conducted to identify and mitigate hazards. 

Flammable: A substance capable of being easily ignited and continues to burn. 

Hot Work: Work such as welding, brazing, cutting, soldering, or other fire or spark-producing operations. 

Responsibilities 

Management is responsible for implementing, supporting, and enforcing this program. 

Supervisors are responsible for being familiar with this program and complying with the requirements. Supervisors have the added responsibility of aiding and ensuring employees adhere to the requirements as well. Supervisors are responsible for: 

• Promoting alternatives to hot work being conducted in the field and using hot work designated areas as a primary option 
• Ensuring combustibles are either moved or protected from ignition sources 
• Validating that authorization for hot work has been granted by management’s appointed hot work authorizer 
• Ensuring that the hot work task performer approves conditions as safe prior to beginning work 
• Verifying that fire protection and extinguishing equipment are available and sufficient for the hazards present 
• Ensuring fire watchers are available and maintaining their posts 

Employees are responsible for being familiar with this program and complying with the requirements where applicable. 

A fire watch must: 

• Have fire extinguishing equipment readily available and be trained in the use of the equipment 
• Be familiar with the mitigations in the hot work permit 
• Sound an alarm in the event a fire 
• Ensure a watch is kept for fires in all affected areas 
• Attempt to extinguish if a fire or smolder is within the capability of the extinguishing equipment provided 
• Maintain the post and monitor for fires for 30 minutes after the completion of welding or cutting operations 
• Have another trained fire watch relieve him/her if the primary fire watch must leave for any reason 

Job and Worksite Requirements 

Jobsite Precautions 

The following list contains general safeguards that must be implemented; however, this is not an exhaustive list: 

• If the equipment or object that hot work is to be conducted on cannot be relocated to a welding area, then all fire hazards in the vicinity must be relocated to a safe place. 
• Welding equipment such as cables and welders should be placed so that passageways, stairs, and ladders are kept clear. 
• If the equipment or object that hot work will be conducted on cannot be moved and all fire hazards cannot be removed, then alternative hazard mitigations must be used such as assigning fire watches. These may also include shielding or guards that contain the heat, sparks, or slag to prevent contact with hazardous materials or areas. 
• In areas where combustible materials such as paper clippings, wood shavings, or textile fibers are on the floor, the floor must be swept or otherwise cleaned for a radius of 35 feet. 
• If the floor material of construction is flammable, it must be dampened or protected by fire-resistant shields. If working on a surface that was wetted to prevent fires, personnel who may be operating hot work equipment should be protected from shock. 
• Combustible materials must be protected from exposure to sparks where there are floor openings such as grating, cracks in the flooring, openings in walls, or open or broken windows. 
• Ducts or conveyor systems that can potentially carry sparks to other areas must be protected or shut down for the duration of hot work. 
• Extinguishing equipment such as fire extinguishers, dry chemical extinguishing agents, hoses, or buckets of water must be available for instant use. 
• Extinguishing equipment should be selected based on the nature and quantity of combustible materials which could potentially be exposed to sparks. 
• The following materials must be moved or protected prior to hot work beginning: 
• Combustible materials nearer than 35 feet to the point of hot work 
• Combustible materials more than 35 feet away from the point of work that can easily be ignited by sparks 
• Wall or floor openings within a 35-foot radius that may expose combustible materials in adjacent areas 
• Combustible materials on the opposite side of metal partitions, walls, ceiling, or roofs that may be ignited through radiation or conduction heat transfer 

Designated Hot Work Areas 

Designated hot work areas must meet the following requirements: 

• Floors swept and cleaned of combustibles within 35 feet of work area 
• Flammable and combustible liquids and materials maintained 35 feet from work area 
• Adequate ventilation which provides 20 air changes per hour 
• At least one 10-pound dry chemical fire extinguisher within 35 feet of the work area 
• Protective dividers such as welding curtains or noncombustible walls provided to contain sparks 

Areas Prohibited from Conducting Hot Work 

Hot work must not be conducted in the following: 

• Those identified by management as hot work prohibited 
• Buildings equipped with fire sprinkler systems that are impaired 
• Any area which has an explosive atmosphere due to gas mixtures, combustible dust, or any area that may gain an accumulation of gasses or dusts during the hot work process 
• Areas near large quantity storage areas of combustibles such as hay, cotton, or paper 
• Welding and cutting on pipes or other metal that may conduct enough heat through conduction to start a fire 
• In areas where there is a dust accumulation of greater than 1/16 inch within 35 feet of the hot work area 

Hot Work Permit Requirements 

Hot work permits will be used whenever hot work is conducted outside of designated welding areas. The hot work permit should be used as a checklist to ensure all hazards are mitigated prior to work commencing. Fire watches and employees conducting hot work must both be informed of the mitigations listed on the hot work permit and must take responsibility for ensuring those mitigations are in place throughout the duration of work. 

In addition, when conducting welding outside the designated area, the following requirements will apply: 

• A hot work permit will be completed prior to welding operations beginning 
• Fire watches will be provided 
• Plastic materials will be covered with welding tarps 
• Welding shields will be used to protect other workers in the area when applicable 
• Respiratory protection will be used when an exposure assessment is deemed necessary 
• When welding is finished, hot metal will be marked or guarded to prevent harm to other workers 

Fire Watch Requirements 

Fire watches are required to be present whenever welding or cutting is performed in locations where fires that may be other than minor can develop. The fire watch is required to: 

• Have extinguishing equipment immediately available and be trained in the use of the extinguishing equipment 
• Be aware of how to contact emergency services in the event of a fire 
• Patrol the area in watch for a fire in all exposed areas 
• Only attempt to extinguish the fire within the capacity of the equipment available after first stopping hot work and calling emergency services 
• Continue to patrol the area for an additional 30 minutes to ensure there are no smoldering fires after all hot work is completed 

Physical Hazard Protection & PPE 

If hot work needs to be conducted at heights such as on platforms, scaffolding, or catwalks, employees will be protected against falls. This may be accomplished in several ways including the use of scaffolds, railings, harnesses, lanyards, or other methods that are equally protective. If harnesses and lanyards are to be worn, they must be of a durable material and flame or fire resistant. 

When conducting arc welding or arc cutting, it is important that helpers be provided with eye protection. This eye protection is intended to prevent arc flash burns and may include: 

• Goggles or other suitable eye protection to be used during all gas welding or cutting operations using oxygen. 
• Transparent face shields or equally protective goggles for both hot work task performers and fire watches if necessary. The type of eye protection selected should be based on the need to protect the face and/or eyes. 
• Goggles for brazing must be evaluated. 

The PPE chosen to conduct hot work such as helmets and hand shields must be made of insular material for heat and electricity. All helmets and shields used must not be of flammable material. This equipment must be capable of withstanding sterilization. The PPE selected must protect the face, neck, and ears from radiant energy from the hot work itself. All eye protection must be compliant with ANSI Z87.1. The shade of eye protection used should be selected based on the type of work performed. 

Hot work may only be conducted when the employee has obtained the proper PPE. The following must be used for welding, cutting, and brazing: 

Eye and Face Protection 

• A helmet with filter lenses and cover plate that complies with ANSI Z87.1 
• Safety glasses with side shields 

Respiratory Protection 

• A respiratory protection assessment will be used to determine if there is a need for employees to wear respirators 
• Respirators will be provided by the company when required in accordance with OSHA requirements 
• Welding and cutting operations will be adequately ventilated to prevent the accumulation of toxic materials 

Head and ear protection 

• A fire-resistant welder’s cap under helmet as needed 
• Approved ear plugs 

Foot protection 

• Pants with cuffs should not be worn when welding or cutting 
• Safety toe shoes where required 

Hand protection 

• Flame resistant welding gloves that are dry and free from holes or other serious damage 

Body protection 

• Oil-free clothing approved for hot work 
• Leather aprons, capes, and sleeves as needed 



Specific Operations 

Welding or Cutting Containers or Tanks 

Used containers may not be welded or cut unless they have been cleaned thoroughly enough to ensure there are no flammable materials present such as grease, acids, or substances that may produce toxic vapors when cut. Any piping or lines connected to the drum or vessel must be disconnected or blanked prior to hot work being performed. 

Confined Spaces 

All spaces, cavities, and containers must be purged of air prior to cutting or welding. Ventilation must be provided. All gas cylinders and welding machines must be stationed outside the confined space at all times. 

When employees must enter a confined space through a small opening such as a manhole, means to quickly provide rescue will be provided by the company. Respiratory protection must also be evaluated prior to work being conducted. 

Screening and Shielding  

When welding is conducted in an area that is shielded or screened on all sides, the screens must be placed to allow for adequate ventilation. The placement must ensure that ventilation is not restricted. If possible, screens should be mounted to 2 feet above the floor level unless work is conducted at floor level. That will allow for air flow. 

Cylinders 

Compressed gas cylinders will be DOT approved and legibly marked. All cylinders will be secured in an upright position at all times, except for short duration transport. Cylinders must be kept away from sources of heat. All cylinders will be used and maintained in accordance with OSHA requirements. 

Training Requirements 

Both current and new employees must be trained prior to conducting hot work on the following: 

• General safety precautions associated with the work site, recognition of hazards, mitigation of hazards, and preventative measures related to common ignition sources, dust accumulations, and smoking 
• Specific procedures and safety practices that may apply to job tasks including any involving hot work 

In addition, the company will ensure employees who work in welding and cutting operations are trained to work safely with these systems. This training will include: 

• Awareness of welding hazards 
• Proper handling, moving, and storage of fuel cylinders 
• Ensuring equipment is equipped with proper safety devices 
• Conducting testing and inspection of equipment 

Fire watches 

Employees who will be conducting fire watch duties must be trained in the responsibilities of the fire watch. The training should include proper use of extinguishing equipment and how to contact help in the event of a fire. The training should also include specifics on how to patrol for fires, when to extinguish fires, and when to sound the alarm for help. Fire watches must also understand the requirements to maintain their posts and continue to be vigilant for fires 30 minutes after hot work has ceased. 

Recordkeeping 

It is critical that all training is documented. 

All hot work permits must be filed and maintained on record for at least three months.