For many, the term “hot work” might conjure up an image of a vast mill, where molten ore is ever present in vats, being poured into casting molds amidst a shower of sparks and extreme radiant heat. Or perhaps one imagines a metal worker operating a plasma table cutting thick sheets of steel like a hot knife through butter. While these are definitely both examples of hot work, the term covers a much wider array of activities performed in varied work environments.

According to the National Fire Protection Association, hot work is defined as “any activity or process that involves open flames or that generates sparks or heat.” This would include the examples listed above but also welding, grinding, burning, certain types of cutting, brazing, soldering or similar activities. Basically, any type of work that creates an ignition source could be considered as “hot work.”

Hot work not only has the potential to start fires and cause death and destruction through the direct ignition sources of sparks, flames and the like, but can also cause fires and possibly explosions through indirect methods. NFPA research indicates that an average of 4,580 structure fires occur each year, resulting in over 170 injuries and more than 20 deaths. These fires also cause an estimated $484 million in annual property damage.

How can hot work dangers be mitigated? The first and most effective measure is to ask, “Is hot work necessary?” or “Can another option be employed?” If an alternative solution can be used safely and effectively, then hot work can be avoided completely and the risk is eliminated. If not, then proper planning, training and procedures for analyzing the workspace, monitoring the work and surroundings during and after the hot work is complete are essential.

Best practices include developing a prework checklist to ensure that the workplace has been properly prepared to eliminate as many risks as possible. Also, a hot work permit program should be developed and put in place.

NFPA research indicates that an average of 4,580 structure fires occur each year, resulting in over 170 injuries and more than 20 deaths. These fires also cause an estimated $484 million in annual property damage.

The purpose of a hot work permit is to certify individuals trained in the planned scope of work establishing a checklist of safeguards and procedures to be followed before, during and after the work is completed. The responsibility for hot work is assigned to management, defined as “all persons, including owners, contractors, educators, or designated agents, who are responsible for hot work operations” per the NFPA.

A hot work permit is valid for one day and issued by the Permit Authorizing Individual (PAI), who is identified and designated by management. The permit should be printed on a highly visible background and posted in a conspicuous location where the work will be performed. The individual issuing the permit must have the skills, knowledge, training and experience relevant to the work to be performed. Typically, this would be the resident Safety Manager or equivalent. A great example of a hot work permit can be found here.

Several of the recommended controls include making sure all workers are trained properly, identification and use of all appropriate Personal Protective Equipment, eliminating or covering any combustible material within 35 feet of the work area, making certain that proper ventilation and fire extinguishers are present and requiring that a fire watch is maintained during the hot work and for a minimum of one hour after the hot work has ended. Local fire authorities should be notified of the scope of hot work and a fire code permit should be obtained before any hot work begins.

While there are inherent dangers involved whenever hot work must be performed, proper planning, preparation, execution and follow-up can reduce the risk and help produce a safe outcome. For more detailed information, please reference NFPA 51B, or OSHA 1910.252. Again, the lowest risk option is to implement an alternative to hot work. When that is not feasible, following the regulations and precautions laid out by the organizations above will help to guarantee a safe outcome.