Hot Work Resources:
For employees: Hot Work resources will provide workers the basic information to stay informed, be aware of specific responsibilities and establish basic understanding of company requirements. Safe work practices help to prevent accidents and injuries on the job. By following established safety procedures, workers can protect themselves and their colleagues from harm, and help to ensure that the work environment is safe and healthy.
For employers: Safe work practices and procedures are important for employers for several reasons. First and foremost, they help to prevent accidents and injuries on the job, which can result in costly workers' compensation claims and potential legal liabilities. Implementing safe work practices and procedures can also help to improve productivity by reducing downtime and ensuring that workers can perform their tasks efficiently and effectively. In addition, a strong emphasis on safety can enhance the reputation of the company, help to attract and retain high-quality employees.
In this section:
What is Hot Work
Hot work hazards, tools used, hazard controls and PPE
Responsibilities for employees & employers
Hot Work Programs
Safe Work Practices
Safe Work Procedures PDF
Welding Safety, Hazard, Precautions & PPE
Before performing hot work, what are some general good practices?
Hot Work, also known as "Welding and allied processes", is defined as any process that could potentially cause ignition when a flammable material is present or poses a fire hazard. This encompasses activities like welding, brazing, cutting, soldering, and thermal bonding, where heat, sparks, and particles produced can ignite flammable, combustible, or explosive materials and atmospheres.
In Alberta, hot work is regulated under the Occupational Health and Safety Act, Regulation and Code, with the Fire Safety Act also applicable. Whenever feasible, compliance with the latest version of the CSA standard CSA-W 117.2, “Safety in Welding, Cutting and Allied Processes" is recommended.
Various parties, including employers, employees (including dependent contractors), and other competent individuals like contractors, constructors, suppliers, owners, or self-employed persons, bear responsibility for meeting the relevant occupational health and safety requirements for hot work as stipulated by the Act, regulations, and standards.
Before commencing any work classified as "hot work" in the workplace, specific processes and procedures must be developed, adhered to, and integrated into the workplace to mitigate injuries, illnesses, and incidents.
Failure to comply with hot work requirements carries various risks, including:
Injury or fatality
Property damage
Financial consequences such as downtime costs, fines, and business loss
Convictions under the OHS Act
Convictions under the Fire Safety Act
Convictions under the Criminal Code
Hazards, Tools Used & Common PPE:
Typical hot work processes include welding, soldering, cutting, brazing, burning, and the use of powder-actuated tools or similar operations that produce fire outside designated hot work areas. In situations where flammable materials are absent, industrial processes such as grinding and drilling are considered cold work.
Hazards of Hot Work:
Fire and burn injuries:
Sparks (Spatter): Spatters generated during welding, cutting, grinding, or other activities can easily ignite fuel, initiating fires.
Molten metals, slag, or swarf: Molten metal and slag generated from cutting or welding activities have high temperatures and can rapidly ignite nearby materials.
Heat conduction in metals: Metals such as pipes and channels heat up quickly during hot work, and heat can conduct from one end to another. If a flammable atmosphere or material is present at the other end, it may catch fire.
Explosive environment: Vapors or gases from flammable materials in the air can ignite easily during hot work, necessitating the removal of such gases before starting any hot work.
Burn Hazard: Molten metals or hot surfaces can cause burns if touched during hot work.
Health hazards:
Fumes: Welding or cutting activities generate hazardous fumes that can affect the respiratory system of the welder. Fumes from residue deposits on cutting/welding surfaces are also harmful.
Radiation: Welding produces UV light that can damage the eyes if exposed.
Electrocution and electrical fire: Welding machines, grinding machines, and other equipment used for hot work are powered by electricity, posing a risk of electrocution.
Mechanical hazards:
Crushing / pinch points
Cutting
Fluid injuries
Injection injuries
Compressed gas hazards:
Fume inhalation
Chemical exposure
Injection injuries
Fire and explosive
In proper ventilation
Safety Hazards:
Working at heights.
Working in confined spaces.
Exposure to flying particles that can enter the eyes or skin.
Cuts and stabs from sharp metal edges.
Injuries from other equipment (e.g., power tools like grinders, chippers, drills, etc.).
Slips, trips, or falls due to the job's location or environmental conditions.
Crushing, pinch points, severing
Welders flash (another name for photokeratitis, a painful eye condition that can happen when unprotected eyes are exposed to ultraviolet (UV) rays.)
Psychological Hazards:
Work demands and deadlines may lead to stress on the job.
Some welders may be required to work shifts or extended hours, which can have health effects.
Hot Work safety precautions & control measures:
Before hot work can commence in the workplace, specific processes and procedures must be followed and implemented to prevent injuries, illnesses, and incidents.
Hot work management programs should be established in the workplace to control or eliminate hot work hazards and risks.
These programs include:
Development of policies, procedures, forms, and permits.
Assignment of responsibilities and accountabilities for all aspects of hot work.
Training and certification
Personal protective equipment
Ventilation
Fire prevention
Inspect equipment
Emergency preparedness
Risk assessments
Supervision and Monitoring
Personal protective equipment (PPE)
Personnel conducting welding, cutting, and grinding operations must wear appropriate protective equipment before commencing work.
This includes:
Eye and Face Protection: Suitable eye protection to shield against sparks, debris, and intense light, such as welding goggles or face shields.
Shatter-Resistant Face Shields: Face shields specifically designed to resist shattering during grinding operations.
Helmets: Helmets compatible with welding hoods, face shields, etc., to protect the head and face.
Protective Clothing: Clothing designed to minimize the risk of ignition, burns, and exposure to hot sparks or electric shocks, including:
Flame-resistant gloves for welders and cutters.
Flame-resistant aprons to shield the front of the body from sparks and radiant energy.
Leggings, especially for heavy work, made of flame-resistant or equivalent material to provide additional protection to the legs.
Ear Protection: Measures to control noise generated by hot work, with ear muffs or ear plugs to be used when noise levels exceed allowable limits (85dBA).
Respiratory Protective Equipment (RPE): When ventilation systems are inadequate to reduce airborne contaminants to acceptable levels, or when such controls are not feasible, personnel must use RPE to protect against hazardous concentrations of airborne contaminants.
Tools commonly used during "hot work" include:
Electric, oxyacetylene, laser, or similar welding or cutting equipment
Grinders
Gas torches or blow lamps for brazing, soldering, thawing pipes, torch-applied flooring or roofing materials, or removal of any materials.
Ergonomic:
Many injuries sustained by welders stem from strains, sprains, and work-related musculoskeletal disorders (WMSDs). Welders frequently encounter tasks such as:
Lifting or moving heavy objects.
Working in awkward positions for extended periods.
Handling and maneuvering heavy welding guns.
Engaging in repetitive motions.
See OSH Answers document on Welding - Ergonomics for more information.
Hazard Types and Controls:
A hazard refers to a situation, condition, or behavior that has the potential to cause harm or pose a danger to the health or safety of individuals involved.
Various sources of hazards are present when performing Hot Work in the workplace, encompassing health, safety, and physical hazards, as well as risks of electrical shock, fire, explosion, and exposure to fumes and gases.
Hazard Controls:
Before any work commences in the workplace, employers bear specific responsibilities according to Alberta OHS Code Part 2 including:
Assessing and identifying all existing and potential hazards.
Preparing a report (Hazard Assessment/FLHA/Pre-job).
Repeating assessments when necessary.
Taking reasonable measures to:
(a) Eliminate the hazard, or
(b) If elimination is not reasonably practicable, control the hazard.
Through the application of the hierarchy of controls, methods can be employed to reduce the risk of hazards to
workers:
Elimination ( MOST EFFECTIVE)
Substitution
Engineering Controls
Administrative
PPE (LEAST EFFECTIVE)
Consideration may be given to substituting hot work with other methods, including:
Instead of: Use:
Saw or torch cutting Manual hydraulic shears
Welding Mechanical bolting
Sweat soldering Screwed or flanged pipe
Torch of radial saw cutting Mechanical pipe cutter
Responsibilities within a Hot Work Program for employees & employers:
There are multiple layers of workers involved in hot work, and all levels of employees have responsibilities when it comes to performing Hot Work in the Workplace.
These levels include:
Management
Program Administrator
Supervisor
Hot Work Approver
Authorized Personnel
Fire Watch
Other Personnel
For the purpose of this resource center, we will review the responsibilities of Management (Employer) and Authorized Personnel (Employee).
An employers must ensure that all levels of responsibilities as required are outlined within your company specific program.
Management must:
Ensure every reasonable precaution is taken to ensure the health and safety of persons at or near the workplace. This is commonly known as the General Duty Clause and is a core part of the Internal Responsibility System (IRS); covering any circumstances that could impact the health and safety of persons in the workplace, including those not specifically addressed in the Act or regulations.
Provide and maintain equipment, machines, materials, or things that are properly equipped with safety devices.
Ensure all employees performing or supervising hot work are competent and aware of hazards by providing necessary information, instruction, and training.
Conduct business activities in a manner that does not expose employees to health and safety hazards.
Comply with the Occupational Health and Safety Act and regulations.
Assess all tasks, worksites prior to work beginning
Workplace Monitoring:
Notify the Joint Occupational Health and Safety Committee (JOHSC) or safety representative about workplace OHS inspections or monitoring reports.
Provide reasonable notice and explanation of monitoring procedures to observers.
Notify observers of any equipment malfunctions or process alterations.
Authorized workers must:
Authorized personnel includes employees or contractors who are trained to perform hot work activities including soldering, welding, pipe-cutting, heat-treating, grinding, thawing pipes, hot riveting, torch-applied roofing and any other application involving heat, sparks or flames. Duties of authorized personnel include:
Complete all required hot work training.
Seek approval and/or permits before commencing hot work activities.
Perform hot work activities in accordance with established programs.
Inspect designated hot work areas and equipment for hazards before starting work.
Retain control of equipment during hot work operations.
Workplace Monitoring:
Observe workplace OHS monitoring if selected by the JOHSC or safety representative.
Ensure proper handling of compressed gas cylinders and conduct leak tests as necessary.
Inspect surroundings and take precautions to prevent fire or explosion before starting hot work.
Attend to gas supply leaks promptly and ensure repairs are made before resuming work.
To remove all hazardous material or processes that produce combustible, flammable or explosive material, dust, gas or vapor.
To prevent fire or explosion; and,
To protect any person(s) located below the hot work area from sparks, debris and other falling hazards.
Source: ohs.guide.constructionsafetyns.ca/topic/hot_work/#leg_ref_LEG_1_0
The Hot Work Program is a requirement for all employers preforming this type of work in Canada.
Development of a Hot Work Program:
Before any work classified as "Hot work" can commence in the workplace, specific processes must be followed to prevent injuries, illness, and incidents.
Hot work management programs should be implemented in workplaces where hot work is performed to control or eliminate hazards and associated risks.
Development of Policies and Procedures:
Establish policies on where hot work is permitted, when it is allowed, and who is responsible for authorizing, performing, and monitoring hot work activities.
Define procedures for assessing areas before permitting hot work, preparing work areas, handling hot work tools, obtaining hot work permits, and managing hot work in hazardous areas.
A program includes:
1. Policies
· Where hot work is permitted (Sites/ shop locations)
· When hot work is permitted
· Who authorizes, performs, and monitors hot work activities
2. Procedures:
· What must be assessed before permitting/performing hot work in an area or on a process piece of equipment or area
· What to do to prepare an area for hot work
· What to do if hot work cannot be avoided in a particularly hazardous area
· What hot work tools are required
· How to obtain a hot work permit, when they are required, and who can administer them
3. Training:
· Provide training to employees, supervisors, maintenance staff, fire wardens, trained fire watch personnel, and contractors according to their respective roles and responsibilities.
4. Communications:
·Post procedures and policies related to hot work.
·Display signs in areas where hot work is prohibited.
Hot Work permit
Every job site involving hot work requires a permit to document hazards and safeguards in place to prevent fires. Use applicable forms and complete the Hot Work Permit as outlined in program requirements. This permit serves as documentation completed by the hot work contractor and must be posted at the site to inform workers in the area that hot work is being conducted.
Safe Work Practices
For employees:
Adhering to safe work practices is crucial for preventing accidents and injuries in the workplace. By following established safety procedures, workers not only safeguard themselves but also protect their colleagues, contributing to a safe and healthy work environment.
For employers:
Safe work practices and procedures hold significant importance for employers on various fronts. Primarily, they serve to prevent accidents and injuries, minimizing costly workers' compensation claims and potential legal liabilities. Implementing these practices can also enhance productivity by reducing downtime and enabling workers to perform tasks efficiently. Moreover, prioritizing safety can bolster the company's reputation, making it more appealing to prospective employees and aiding in the retention of skilled staff.
Before performing hot work, it's essential to follow general good practices to ensure safety:
Ensure all equipment is in good operating order before work begins.
Confirm that appropriate personal protective devices is available and workers are trained in its proper use, cleaning, and storage.
Thoroughly inspect the work area for combustible materials, and remove or cover them as necessary.
Clear flammable and combustible materials from the work area or shield them with fire-resistant blankets or shields.
Clean combustible materials from floors and keep them wet or covered during work.
Use water only if electrical circuits are de-energized to prevent electrical shock.
Remove spilled grease, oil, or other combustible liquids.
Vacuum combustible debris from ventilation ducts and seal any cracks to prevent ignition.
Ensure appropriate fire extinguishers and first-aid kits are readily accessible.
Seal cracks and close doors and windows to prevent the spread of fire.
Cover surfaces with fire-resistant and heat-insulating materials.
Secure, isolate, and vent pressurized vessels, piping, and equipment as needed.
Inspect the area after work to ensure no surfaces have heated up.
Assign a trained fire watcher during and after hot work to monitor for sparks or slag.
Eliminate explosive atmospheres or shut down processes that produce them before hot work.
Schedule hot work during shutdown periods whenever possible.
Comply with relevant legislation and standards applicable to the workplace.
Following these practices can significantly reduce the risk of accidents and ensure a safe working environment during hot work operations.
Source: Canadian Centre for Occupational Health and Safety link
Ventilation:
Ensure an adequate supply of fresh air and the removal of impure air from the workplace to maintain air quality and prevent harm.
When processes generate harmful impurities that may be inhaled and cause injury, employ mechanical means to prevent inhalation, carry off, dispose of, and prevent the recirculation and re-entry of such impurities.
Ensure that all components of the ventilation system are designed, installed, operated, maintained, and repaired adequately by competent individuals.
Portable Compressed Gas Cylinders:
Ensure safe storage and transportation of all cylinders, protecting them from exposure to corrosive materials or substances that aid corrosion, and preventing them from falling or being struck by falling objects, in compliance with the Fire Safety Act.
Prominently display 'No Smoking' signs and clearly label the storage area with the names of all stored gases.
Prohibit rolling cylinders on their sides, rough handling, or moving them with lifting magnets.
Utilize suitable cradles or platforms for securely holding and lifting cylinders when appropriate lifting mechanisms are not provided on the cylinder.
Hot Work – General Precautions:
Ensure all hot work equipment is erected, installed, assembled, started, operated, used, handled, stored, stopped, inspected, serviced, tested, cleaned, adjusted, carried, maintained, repaired, and dismantled according to the manufacturer’s specifications.
Ensure that only competent individuals perform hot work.
Before commencing hot work, ensure the responsible worker inspects the surroundings and takes adequate precautions to:
Remove all hazardous materials or processes that produce combustible, flammable, or explosive materials, dust, gas, or vapor.
Prevent fire or explosion.
Protect individuals below the hot work area from sparks, debris, and other falling hazards.
If there is a radiation or reflection exposure hazard, provide adequate screens to prevent it from affecting workers or prevent individuals from entering the work area.
Ensure compressed gas hose lines or welding cables are adequately protected from damage.
Ensure operators do not leave electric welding machines unattended without removing the electrode.
Ensure appropriate welding and ground leads are used to securely fasten the electric supply cable, preventing exposure to damage and ensuring the cable cannot be separated from the fittings.
Hot Work – Containers:
Ensure that no individual conducts hot work on a container, pipe, valve, or fitting that has contained or may contain an explosive, flammable, or otherwise hazardous substance, or may become pressurized hazardously, unless a written work procedure is established and adhered to.
The written work procedure should include instructions for:
Disconnecting, blanking off, or relocating pipes, or locking out valves in the closed position.
Additionally, the procedure must outline steps that the competent person must take after ventilation, including:
Examining the area to be welded or processed to ensure it is free from residue.
Testing air samples to ensure that explosive, flammable, or hazardous gases or vapors are reduced to less than 1% of the lower explosive limit in the welding or processing areas.
Providing written certification that work involving heat application can be safely conducted and that conditions in the area to be heated are within predicted and recorded ranges for the entire duration of certification.
When hot work is performed on natural gas or liquids pipelines associated with a natural gas pipeline, ensure that an engineer certifies that the written work procedure complies with API Standards.
Furthermore, prohibit the use of internal combustion engine exhaust to reduce the concentration of flammable and explosive gases and vapors in the area to be welded or processed.
Hot Work – Gas Welding:
Ensure that a gas supply leak test is conducted immediately after connecting the regulator and its flexible connecting hose to a gas cylinder.
Do not conduct gas supply leak tests using substances that are oil, fat, or grease-based.
In the event of a gas leak during gas welding or allied processes, ensure the operator immediately shuts off the gas supply and refrains from resuming work until the leak is repaired.
Install a flashback arrestor between the torch and the fuel gas and oxygen supply to prevent flashback incidents.
Legibly mark or identify hose lines and pipelines used for conveying gases to burners and couplings to prevent interchange of hoses.
Ensure torches are ignited using lighting devices specifically designed for that purpose.
Establish a written health and safety procedure for the manufacturing of acetylene in the workplace, if applicable.
What are some general safe work practices to know?
Welders should be knowledgeable about:
General information and tips related to welding techniques and practices.
Proper selection, use, maintenance, and storage of personal protective equipment (PPE) specific to welding tasks.
Procedures for confined space entry, ensuring safety during welding activities in confined spaces.
Fall protection procedures to prevent falls while working at heights during welding operations.
Lock-out/tag-out procedures to safely isolate energy sources before conducting welding tasks on equipment or machinery.
Safe handling procedures for flammable hazardous products encountered during welding operations.
Safe handling and usage practices for compressed gases used in welding processes.
Safe operation of power tools commonly used in welding activities.
Safe practices for working on ladders, platforms, and scaffolds to prevent falls and accidents.
Techniques for manual material handling (lifting) to avoid injuries during welding-related tasks.
Compliance with relevant standards and regulations when welding boilers, pressure vessels, and pressure piping systems.
All workers, including welders, should:
Adhere to company safety rules and policies related to welding and general workplace safety.
Be familiar with the Workplace Hazardous Materials Information System (WHMIS) and Safety Data Sheets (SDSs) for hazardous materials used in welding.
Report hazards and unsafe conditions promptly to ensure a safe working environment.
Follow good housekeeping procedures to maintain a clean and organized work area, reducing the risk of accidents and injuries.
Safe Work Procedures:
Hot Work Non-Designated Area Procedures:
Basic Precautions: To conduct hot work in a non-designated area, the following minimum precautions must be observed:
Ensure the building fire sprinkler system is operational at the hot work location (if applicable).
Move all combustible materials within 35 feet of the hot work to a safe distance or relocate them.
If combustible materials cannot be moved, protect them with fire retardant covers or shield them with fire retardant or metal guards.
Provide appropriate personal protective equipment (PPE) to employees based on a hazard assessment.
Initiate a fire watch during and for 30 minutes after all hot work has ceased.
Have the hot work approver inspect the hot work area before commencing work.
Issue and post a hot work permit (see Appendix A) approved by the hot work approver.
Additional precautions must be taken if any of the following conditions exist, as determined by the hot work approver prior to commencing work:
Floor Openings/Coverings:
Protect floors from exposure to flames, sparks, slag, or other hot materials if combustible floors or materials are present.
Protection measures may include fire-resistant shields or materials, wetting down floors, covering floors with damp sand, sweeping combustibles from the floor, or other measures deemed necessary.
Wall Openings:
Protect walls from exposure to flames, sparks, slag, or other hot materials if combustible walls, wall openings, pipe penetrations, or ducts are present.
Protection measures may include fire-resistant shields or materials, shutting dampers, assigning a separate fire watch on the other side of the walls, or other measures deemed necessary.
Potentially Explosive Atmospheres:
No hot work shall be conducted if there is a potential for mixtures of flammable gases, vapors, liquids, or dust in the air.
The Program Administrator must review the situation, and air monitoring must confirm that there is no danger of an explosion before hot work can proceed.
Containers:
Do not perform hot work on used drums, barrels, tanks, or other containers until they have been thoroughly cleaned.
The hot work approver must ensure that no flammable materials or substances that could produce flammable or toxic vapors if exposed to heat are present before authorizing hot work on containers.
Hot Work Fact Sheet
Download the Hot Work Fact Sheet that provides an excellent overview of Hot Work Hazards and How to Minimize Hot Work Hazards.
File source: National Fire Protection Association (NFPA)
Workplace Health and Safety Bulletin
Safe Work Permits
Certain safeguards that typically protect workers may need to be removed during repair or maintenance work. In such cases, it's crucial to identify the associated hazards and develop a safe work system to eliminate or control these hazards.
A safe work permit is a document that outlines the work to be undertaken, identifies the associated hazards, and specifies the precautions to be implemented. It ensures that all hazards and necessary precautions are thoroughly evaluated before work commences. Safe work permits should always be utilized when work is conducted by an external agency or employer.
File source: www.alberta.ca/open-government-program.aspx