Product Overview

Summary: This Hot Work Permits and Flame Use SOP provides a clear, step-by-step system for planning, authorising and controlling any work that generates heat, sparks or open flame. It helps Australian businesses prevent fires, explosions and serious injuries while demonstrating due diligence under WHS legislation and insurer expectations.

Hot work such as welding, grinding, cutting, soldering and use of open flame equipment is a leading cause of workplace fires and catastrophic property loss. This Hot Work Permits and Flame Use Safe Operating Procedure sets out a robust, repeatable permit-to-work process that ensures hot work is only carried out when it is absolutely necessary, properly planned and tightly controlled. It guides you through assessing the work area, isolating flammables, implementing fire watch arrangements and verifying that all WHS and insurer requirements are met before a single spark is generated.

Developed for Australian conditions and regulatory expectations, this SOP helps organisations move beyond informal approvals and ad‑hoc controls. It clearly defines who can issue hot work permits, how long they remain valid, what checks must be completed, and how to document fire safety precautions and post-work monitoring. By implementing this procedure, businesses can significantly reduce the risk of fires, explosions, burns and smoke inhalation, improve contractor management, and provide strong evidence of compliance during audits, incident investigations and insurance reviews.

Key Benefits

• Reduce the risk of fires, explosions and burn injuries arising from welding, cutting, grinding and other flame-producing tasks.
• Ensure consistent, auditable hot work permit controls across all sites, shifts and contractors.
• Demonstrate compliance with Australian WHS legislation, insurer requirements and relevant fire safety standards.
• Strengthen contractor management by clearly defining responsibilities, approvals and supervision for hot work.
• Improve emergency preparedness through documented fire watch, isolation, and post-work inspection requirements.

Who is this for?

• Site Supervisors
• WHS Managers
• Maintenance Managers
• Construction Project Managers
• Fabrication Workshop Managers
• Facilities Managers
• Permit-to-Work Coordinators
• Boilermakers and Welders
• Mechanical Fitters
• Contractor Coordinators
• Fire Wardens and Emergency Response Team Leaders

Hazards Addressed

• Ignition of flammable or combustible materials from sparks, slag or hot surfaces
• Fires and explosions in areas containing flammable vapours, gases or dusts
• Burns from contact with hot metals, equipment or molten material
• Smoke inhalation and exposure to hazardous welding and cutting fumes
• Damage to property, plant and critical infrastructure from uncontrolled fire
• Secondary incidents during emergency response, such as slips, trips and falls in low-visibility conditions
• Electrical hazards associated with electric arc welding and powered cutting tools
• Confined space hazards when conducting hot work in tanks, pits or enclosed areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions (Hot Work, Flame Use, Permit Issuer, Fire Watch, Exclusion Zone)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hot Work Risk Assessment and Job Planning
• 6.0 Hot Work Permit Application, Approval and Validity Rules
• 7.0 Pre-Work Area Preparation and Isolation of Flammables
• 8.0 Required PPE, Fire Protection and Monitoring Equipment
• 9.0 Safe Operating Procedure for Hot Work and Flame Use
• 10.0 Fire Watch Duties During and After Hot Work
• 11.0 Post-Work Inspection, Sign-Off and Permit Closure
• 12.0 Controls for Hot Work in Confined Spaces and Hazardous Areas
• 13.0 Contractor Management and Site Induction Requirements
• 14.0 Emergency Response, Fire Reporting and Incident Management
• 15.0 Training, Communication and Competency Verification
• 16.0 Recordkeeping, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and corresponding state and territory WHS Regulations
• Safe Work Australia – Managing the Risk of Fire and Explosions at the Workplace Code of Practice
• Safe Work Australia – Welding Processes Code of Practice
• AS 1674.1: Safety in welding and allied processes – Fire precautions
• AS 1674.2: Safety in welding and allied processes – Electrical
• AS 4839: The safe use of portable and mobile oxy-fuel gas systems for welding, cutting, heating and allied processes
• AS/NZS 1674.4: Safety in welding and allied processes – Fume minimization
• AS 1851: Routine service of fire protection systems and equipment
• AS 3745: Planning for emergencies in facilities