Product Overview

Summary: This Welding and Hot Work Permit Safe Operating Procedure sets out a clear, step-by-step system for planning, authorising, and controlling all welding and hot work on site. It helps Australian businesses prevent fires, explosions, and serious injuries while demonstrating robust compliance with WHS obligations and insurer expectations.

Welding, cutting, grinding and other hot work are routine tasks across construction, manufacturing, maintenance and repair, but they are also a leading cause of workplace fires and serious injuries. This Welding and Hot Work Permit Safe Operating Procedure provides a structured permit-to-work system that ensures hot work is only carried out when it is safe to do so, and under clearly defined controls. It guides you from initial risk assessment and isolation of combustibles through to permit issue, work supervision, fire watch, and post-work monitoring.

Developed for the Australian WHS landscape, this SOP helps businesses align with legislative duties and recognised good practice for hot work control. It solves common problems such as inconsistent supervision, poor communication between contractors and site management, and gaps in documentation that can be exposed after an incident. By implementing this procedure, you create a defensible, auditable process that protects workers, plant and property, supports insurance requirements, and gives supervisors the confidence to either approve or stop hot work based on clear criteria.

Key Benefits

• Ensure hot work is only undertaken under a formal permit system with clear approval, control, and sign-off steps.
• Reduce the risk of fires, explosions and burns by systematically identifying and controlling ignition sources and combustible materials.
• Demonstrate due diligence and WHS compliance through documented risk assessments, permits, and supervision records.
• Standardise how employees and contractors plan, conduct and monitor welding and hot work across all sites.
• Support insurance and regulatory investigations with clear, traceable evidence of hot work controls and decision-making.

Who is this for?

• WHS Managers
• Site Supervisors
• Workshop Supervisors
• Maintenance Managers
• Construction Project Managers
• Facility Managers
• Welders and Boilermakers
• Mechanical Fitters
• Contractor Coordinators
• Fire Wardens and Emergency Response Coordinators

Hazards Addressed

• Fire ignition from sparks, spatter and hot slag contacting combustible materials
• Explosion risks in confined spaces or areas with flammable vapours, gases or dusts
• Burns and eye injuries from arc flash, hot metal and molten slag
• Electric shock from welding equipment and power supplies
• Exposure to welding fumes and gases, including metal fumes and ozone
• Radiation exposure from welding arcs (UV and IR)
• Oxygen depletion and toxic atmospheres during hot work in confined spaces
• Noise exposure from cutting, gouging and grinding operations
• Trips, slips and falls from poorly managed leads, hoses and work layouts
• Property damage and business interruption from uncontrolled hot work incidents

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions (Welding, Hot Work, Permit, Fire Watch, Confined Space, etc.)
• 3.0 Roles and Responsibilities (Permit Issuer, Permit Holder, Fire Watch, Supervisors, Workers)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Pre-Work Planning and Risk Assessment Requirements
• 6.0 Hot Work Permit Process and Workflow
• 7.0 Site Preparation and Isolation of Combustibles
• 8.0 Control Measures for Welding and Hot Work (Ventilation, PPE, Fire Protection, Electrical Safety)
• 9.0 Special Requirements for Confined Spaces and Hazardous Areas
• 10.0 Fire Watch Duties and Post-Work Monitoring Periods
• 11.0 Personal Protective Equipment (PPE) Requirements and Minimum Standards
• 12.0 Equipment Inspection, Maintenance and Tagging Requirements
• 13.0 Contractor Management and Induction for Hot Work
• 14.0 Emergency Procedures and Incident Response for Hot Work Events
• 15.0 Recordkeeping, Permit Retention and Audit Requirements
• 16.0 Training, Competency and Authorisation of Personnel
• 17.0 Review, Consultation and Continuous Improvement of the Procedure

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulations 2011 (Cth and relevant state/territory variants)
• Safe Work Australia – Code of Practice: Welding Processes
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Confined Spaces
• 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/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 2161 series: Occupational protective gloves