Product Overview

Summary: This Hot Work Permit Safe Operating Procedure provides a clear, step-by-step system for planning, authorising and controlling all hot work activities on site. It helps Australian businesses manage ignition risks, protect people and property, and demonstrate due diligence under WHS legislation whenever welding, cutting, grinding or other spark-producing tasks are carried out.

Hot work – including welding, oxy cutting, grinding, soldering and other flame or spark-producing tasks – is one of the most common causes of workplace fires and serious property damage in Australia. This Hot Work Permit Safe Operating Procedure sets out a robust, repeatable process for assessing hot work, issuing permits, implementing controls and confirming the area is safe before, during and after the job. It provides a practical framework that can be applied across construction sites, workshops, manufacturing plants, utilities, and building maintenance environments.

The SOP guides your team through pre-work hazard identification, isolation of flammable materials and services, atmospheric testing where required, fire watch arrangements, and post-work monitoring so that smouldering materials are detected before they become an incident. It also defines clear roles and responsibilities for permit requesters, permit issuers, hot work operators and fire watchers, reducing confusion and reliance on informal practices. By implementing this procedure, organisations can reduce fire risk, protect workers and assets, streamline contractor management, and provide documented evidence of WHS compliance and risk management for insurers, regulators and clients.

Key Benefits

• Reduce the risk of fires, explosions and property damage arising from welding, cutting, grinding and other hot work activities.
• Ensure a consistent, documented permit-to-work process that satisfies WHS due diligence and insurer expectations.
• Clarify responsibilities between supervisors, permit issuers, contractors and fire watchers to prevent gaps in control.
• Improve pre-job planning by systematically identifying ignition sources, flammable materials and required isolation controls.
• Strengthen emergency readiness with defined fire watch requirements, equipment checks and escalation procedures.

Who is this for?

• Site Supervisors
• WHS Managers
• Construction Project Managers
• Maintenance Managers
• Facilities Managers
• Workshop Supervisors
• Fire Safety Officers
• Permit Issuers / Authorised Persons
• Contractor Coordinators
• Plant Managers

Hazards Addressed

• Fire ignition from sparks, slag, hot surfaces and molten metal
• Explosion risks in areas with flammable gases, vapours, dusts or liquids
• Ignition of concealed combustible materials in walls, ceilings and voids
• Burns and heat stress to workers performing hot work
• Smoke inhalation and exposure to combustion products
• Damage to electrical, gas or fuel services from uncontrolled hot work
• Secondary incidents from inadequate post-work inspections (smouldering materials)
• Inadequate emergency access due to poor work area setup

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions (Hot Work, Permit Issuer, Fire Watch, Exclusion Zone, etc.)
• 3.0 Roles and Responsibilities
• 4.0 Competency, Licensing and Training Requirements
• 5.0 Hot Work Permit Requirements and Validity
• 6.0 Pre-Work Risk Assessment and Job Planning
• 7.0 Isolation of Services and Control of Flammable Materials
• 8.0 Required PPE and Fire Protection Equipment
• 9.0 Hot Work Area Preparation and Exclusion Zones
• 10.0 Atmospheric Testing and Confined Space Considerations
• 11.0 Step-by-Step Hot Work Permit Issue Process
• 12.0 Supervision, Monitoring and Fire Watch Duties
• 13.0 Post-Work Inspections and Permit Closure
• 14.0 Emergency Procedures and Incident Response
• 15.0 Recordkeeping, Audit and Review
• 16.0 References and Applicable Legislation/Standards

Legislation & References

• Work Health and Safety Act 2011 (Cth and corresponding state and territory legislation)
• Work Health and Safety Regulations 2011 (Cth and corresponding state and territory regulations)
• Safe Work Australia – Model Code of Practice: Managing the Risk of Plant in the Workplace
• Safe Work Australia – Model Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• AS 1674.1: Safety in welding and allied processes – Fire precautions
• AS 1674.2: Safety in welding and allied processes – Electrical
• AS/NZS 4836: Safe working on or near low-voltage electrical installations and equipment (where electrical isolation is required)
• AS 1940: The storage and handling of flammable and combustible liquids
• AS 1851: Routine service of fire protection systems and equipment