Product Overview

Summary: This Hot Work Safety Standards Safe Operating Procedure sets out a clear, step-by-step system for planning, authorising and carrying out hot work safely in Australian workplaces. It helps businesses control ignition sources, manage fire risk, and demonstrate compliance with WHS obligations when welding, cutting, grinding or using open flames.

Hot work such as welding, oxy-cutting, grinding, soldering and the use of open flames is a leading cause of preventable fires, serious burns and property damage across Australian worksites. This Hot Work Safety Standards SOP provides a structured, defensible framework for managing those risks, from the initial assessment and permitting process through to post-work fire watch and sign-off. It translates WHS and fire safety requirements into practical, easy-to-follow steps that can be applied in construction, manufacturing, workshops, utilities, facilities maintenance and shutdown environments.

The procedure helps businesses formalise their hot work controls by standardising how jobs are planned, authorised and monitored. It details how to assess the work area, identify combustible materials, control flammable atmospheres, specify appropriate PPE, and coordinate with fire protection systems and local emergency procedures. By implementing this SOP, organisations can reduce the likelihood of fires and explosions, protect workers and assets, and demonstrate due diligence under Australian WHS legislation and insurance requirements. It also supports consistent training, clearer communication between supervisors and contractors, and stronger evidence of compliance during audits and incident investigations.

Key Benefits

• Reduce the risk of fire, explosion and burn injuries associated with welding, cutting, grinding and other hot work activities.
• Ensure consistent use of a formal Hot Work Permit system aligned with Australian WHS and fire safety expectations.
• Standardise planning, isolation and fire watch practices across projects, contractors and work locations.
• Demonstrate due diligence and compliance to regulators, clients, insurers and principal contractors.
• Improve worker competence and confidence through clear, task-specific instructions and checklists.

Who is this for?

• WHS Managers
• Site Supervisors
• Maintenance Managers
• Construction Project Managers
• Fabrication Workshop Supervisors
• Facility Managers
• Permit to Work Coordinators
• Fire Safety Officers
• Welders and Boilermakers
• Mechanical Fitters and Maintenance Technicians

Hazards Addressed

• Ignition of nearby combustible materials from sparks, slag and hot metal
• Fire and explosion in areas with flammable vapours, gases or dusts
• Burn injuries from contact with hot surfaces, molten metal or flames
• Eye damage from arc flash, sparks and flying particles
• Inhalation of welding fumes, gases and combustion by-products
• Damage or impairment of fire detection and suppression systems during hot work
• Confined space hazards when conducting hot work in tanks, pits or vessels
• Electrical hazards associated with welding equipment and power leads

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions (Hot Work, Hot Work Area, Fire Watch, Permit Issuer, etc.)
• 3.0 Roles and Responsibilities
• 4.0 Competency, Training and Authorisation Requirements
• 5.0 Pre-Work Planning and Risk Assessment
• 6.0 Hot Work Permit Process and Controls
• 7.0 Site Preparation and Isolation of Hazards
• 8.0 Personal Protective Equipment (PPE) Requirements
• 9.0 Safe Operating Procedure for Common Hot Work Tasks
• 10.0 Fire Prevention, Fire Watch and Fire Protection Measures
• 11.0 Special Considerations for Confined Spaces and Hazardous Areas
• 12.0 Coordination with Contractors and Other Work Activities
• 13.0 Emergency Response and Incident Reporting
• 14.0 Post-Work Inspection, Fire Watch Duration and Permit Close-Out
• 15.0 Inspection, Monitoring and Continuous Improvement
• 16.0 Document Control and Recordkeeping

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 – Code of Practice: Managing the Risk of Plant in the Workplace
• Safe Work Australia – 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 applicable to hot work near electrical systems)
• AS 1851: Routine service of fire protection systems and equipment
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1337.1: Personal eye protection