Product Overview

Summary: This Hot Work Safe Operating Procedure sets out a clear, step-by-step system for planning, authorising, and safely carrying out welding, cutting, grinding, and other ignition-producing tasks. Designed for Australian workplaces, it helps you control fire and explosion risks, meet WHS obligations, and protect people, property, and production from preventable hot work incidents.

Hot work activities such as welding, oxy-cutting, grinding, soldering, and use of open flames are a leading cause of workplace fires and serious incidents across Australian industry. This Hot Work Safe Operating Procedure provides a robust, practical framework for managing these high-risk tasks, whether they are carried out in a dedicated workshop or in the field on construction sites, in plant rooms, or within operational facilities. It translates WHS legislative requirements and recognised industry good practice into a clear, repeatable process that workers and supervisors can actually follow on the job.

The SOP guides you through the full lifecycle of hot work: from initial job planning, risk assessment, and permit-to-work controls, through to equipment checks, fire watch, and post-work monitoring. It sets out the minimum isolation, housekeeping, and fire protection measures required before any spark is created, and defines roles and responsibilities so there is no ambiguity about who can authorise, perform, supervise, or stop hot work. By implementing this procedure, businesses can significantly reduce the likelihood of fires, explosions, burns, and property damage, while also providing documented evidence of due diligence for regulators, insurers, and clients.

This document is particularly valuable for organisations that undertake hot work in or near combustible materials, confined spaces, process equipment, or live operations. It helps standardise expectations across employees and contractors, supports induction and refresher training, and integrates easily with existing safe work method statements (SWMS), permits, and emergency response plans. The result is a safer, more controlled approach to hot work that protects people and assets while keeping projects moving.

Key Benefits

• Reduce the risk of fires, explosions, and serious burn injuries associated with welding, cutting, and grinding.
• Ensure compliance with Australian WHS legislation and recognised hot work control practices, including permit-to-work systems.
• Standardise how hot work is planned, authorised, and supervised across employees and contractors.
• Demonstrate due diligence to regulators, clients, and insurers through clear, documented control measures.
• Improve worker competence and confidence by providing a consistent reference for training and toolbox talks.

Who is this for?

• WHS Managers
• Site Supervisors
• Maintenance Supervisors
• Workshop Managers
• Construction Project Managers
• Facility Managers
• Boilermakers and Welders
• Mechanical Fitters
• Electricians
• Contractor Coordinators
• Safety Advisors

Hazards Addressed

• Fire ignition from sparks, hot slag, and molten metal
• Explosion risks in flammable atmospheres or near combustible dusts and vapours
• Burns from contact with hot workpieces, equipment, or spatter
• Eye injuries from UV radiation, infrared radiation, and flying particles
• Electric shock from welding equipment and power tools
• Inhalation of welding fumes, metal fumes, and combustion products
• Oxygen depletion or toxic atmosphere in confined or poorly ventilated spaces
• Damage to plant, equipment, and building structures from uncontrolled heat or fire spread
• Trip and entanglement hazards from leads, hoses, and cables associated with hot work equipment

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions (Hot Work, Permit, Fire Watch, Designated Hot Work Area)
• 3.0 Roles and Responsibilities (PCBU, Supervisors, Workers, Contractors, Fire Watch)
• 4.0 Applicable Legislation, Standards and References
• 5.0 Hot Work Risk Assessment Requirements
• 6.0 Hot Work Permit-to-Work Process
• 7.0 Pre-Start Requirements and Site Preparation
• 8.0 Isolation, Housekeeping and Protection of Combustible Materials
• 9.0 Required PPE and Safety Equipment for Hot Work
• 10.0 Equipment Inspection, Set-Up and Maintenance
• 11.0 Step-by-Step Hot Work Operating Procedure
• 12.0 Fire Watch Duties and Post-Work Monitoring Periods
• 13.0 Special Controls for Confined Spaces and Hazardous Areas
• 14.0 Emergency Response, Fire Extinguishing and Incident Reporting
• 15.0 Training, Competency and Authorisation Requirements
• 16.0 Monitoring, Review and Continuous Improvement
• 17.0 Document Control and Record Keeping (Permits, Inspections, Training)

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variations)
• Work Health and Safety Regulations 2011 (Cth and relevant state/territory variations)
• Safe Work Australia – Code of Practice: Managing the Risk of Plant in the Workplace
• Safe Work Australia – Code of Practice: Welding Processes
• 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
• AS 2444: Portable fire extinguishers and fire blankets – Selection and location
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 2161: Occupational protective gloves