MASTER BUILDERS OF

IOWA

CUTTING / WELDING
&
HOT WORK

Property of Master Builders of Iowa / Construction Safety Specialists - 2002

Cutting, Welding, and Hot Work

WARNING: PROTECT YOURSELF AND OTHERS FROM POSSIBLE
SERIOUS INJURY OR DEATH
The purpose of this program is to ensure that employees and property are properly protected against fire,
explosion, and other dangers resulting from hot work. Precautions must take place where welding and
cutting involves the generation of temperatures up to thousands of degrees at which metals melt and
vaporize and where fire may be evident. Other hot work such as grinding that creates a continuous spark or
heat guns that can generate enough heat to start a fire must be taken into consideration. When proper
precautions are taken to protect personnel and property against the heat, involved gases and fumes, electric
shock, and radiation, no harm will result either to personnel or property. In gas welding and cutting, the
handling and storage of compressed gases present other hazards that must be addressed to protect
employees and provide a safe working environment. This program provides detailed procedures and
instructions for safe practices which, must be followed, to protect personnel and equipment from harm or
damage arising from any hot work operation.
Safe practices developed from experience in the use of welding and cutting are described in this program.
Research, development, and field experience have evolved reliable equipment and safe installation,
operation, and servicing practices. Accidents occur when equipment is improperly used or maintained.
Read and understand safe practices in the specific instruction manuals before attempting to install, operate,
or service any equipment. Comply with these procedures as applicable to the particular equipment used, for
personal safety and for the safety of others. Failure to observe these safe practices may cause serious injury
or death.
Responsibilities of installer, user, and serviceman. Installation, operation, checking, and repair of this
equipment must be done by a competent person, experienced with such equipment.
DEFINITIONS:
The following is an alphabetical listing defining terms and abbreviations that each employee
performing hot work must become familiar with. Where applicable, examples are given in order to
provide clarification. These examples are intended to show typical issues that may arise when
following the hot work permit procedure. These issues are not intended to be an all-inclusive.
Rather, it is intended to provide guidance when issuing the hot work permits.
Cutter/Welder:
The individual performing the hot work.
Fire Watch:
A Fire Watch must be in place whenever hot work is performed in locations where other than a
minor fire might develop, or any of the following conditions exist:
A) Combustible material is closer than 35 feet from the point of operation.
B) Combustible materials are more than 35 feet away but are easily ignited by sparks.
C) Wall or floor openings within a 35-foot radius expose combustible materials in adjacent areas
including concealed spaces in walls or floors.
D) Combustible materials are adjacent to the opposite side of metal partitions, walls, ceilings, or
roofs and are likely to be ignited by conduction or radiation.
E) The Fire Watch must have fire-extinguishing equipment readily available and be trained in its
use and limitations. They must be familiar in the procedures for sounding the alarm in the
event of a fire. The Fire Watch must watch for fires in all exposed areas and steel members,
pipes etc. that can transmit heat to walls, ceilings, or combustibles. The designated fire watch's
only responsibility will be to watch for fires!

Property of Master Builders of Iowa / Construction Safety Specialists - 2002

The fire watch shares the responsibility for fire/safety with the cutter/welder. The fire watch should
maintain a constant vigil during the operation (including lunch and coffee breaks) to watch for
stray sparks, ignition sources, or other fire hazards. This individual must be specifically trained in
the use of fire fighting equipment (example, fire extinguisher) and have the equipment readily
available. They must be familiar with the Job site and know how to sound the fire alarm.
Hazard:
A potential for an incident involving employees or property with undesirable consequences,
usually involving a loss of containment of flammable, combustible, or reactive materials.
Hazardous Location:
A hazardous location is where a fire might develop, where there are wall or floor openings within
35 feet, or where there is a presence of combustible material within 35 feet of the hot work
location. A hazardous location is also one where flammable gases, vapors, or combustible dust are,
or may be present in the air in sufficient quantities to produce a fire or explosion.
Hot Work Operations:
Any operation that could cause a source of ignition in a hazardous location. Hot work includes
activities such as; welding, cutting with a torch or plasma cutter, cutting or grinding with a grinder,
use of heat guns or other sources of heat that could support fire.
Source of Ignition:
A source of ignition is a flame, tool spark/heat, static electric charge, internal combustion engines,
or electric spark that would cause a fire or explosion. Any device that creates enough heat to cause
ignition is considered a source of ignition.
Example:

Welding, burning, brazing, soldering, melting, thawing, or any use of an open flame;

Metal removing such as drilling, chipping, abrasive cutting, milling, grinding, etc.;

Internal combustion engines;

Explosive-actuated fastening tools;

Cutting or chipping concrete with or without reinforcements:

Operating non-explosion-proof equipment and tools in an explosion-proof area. Includes

battery-powered equipment and tools;

Operating any cleaning device utilizing a metal or any other material that can produce
sparks;

Work on live electrical circuits of any voltage in hazardous locations and,

Other hot work such as a heat gun that can generate enough heat to start a fire.

There have been several incidents that involved the failure to follow required practices
- Welding sparks caught a conveyor on fire. The fire was not detected until several hours later.
the fire destroyed a container storage area.

Property of Master Builders of Iowa / Construction Safety Specialists - 2002

- A welder was hospitalized when an electrode was jammed into his eye due to electric shock from
an arc welder.
- Oxygen and acetylene bottles have been known to become missiles due to valves broken off.
- A welder was killed due to electric shock from a welder that had poorly maintained welding
leads.
- A fire destroyed a building under renovation when a grinding operation ignited a pile of
combustible materials. A fire extinguisher was not available to extinguish the fire.
- A flammable container did not have a lid in place when a grinding operation ignited rags in the
container.

NOISE
There are two good reasons to use hearing protection:
1) Ear plugs or earmuffs will help keep sparks or metal out of your ears, as well as dust and dirt.
2) Hearing protection can help prevent hearing loss due to noisy equipment, power sources, and associated
work.

PREVENTING ELECTRIC SHOCK

The electrode and work (or ground) circuits are electrically "hot" when the welder is on. Do not touch these
"hot" parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or
semiautomatic welding gun are also electrically "hot".
Insulate yourself from work and ground using dry insulation. When welding in damp locations, on metal
framework, floors, gratings or scaffolds, and when in positions such as sitting or lying, make certain the
insulation is large enough to cover your full area of physical contact with work and ground.
Always be sure the work cable makes a good electrical connection with the metal being welded.
The connection should be as close as possible to the area being welded.
Ground the work or metal to be welded to a good electrical (earth) ground.
Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe
operating condition. Replace damaged insulation.
Never dip the electrode in water for cooling.
Never simultaneously touch electrically "hot" parts of electrode holders connected to two welders
because voltage between the two can be the total of the open circuit voltage of both welders.
A welder or helper working on platforms, scaffolds etc. must be protected against falling. This may be
accomplished by the use of guard railings, personal fall protection, nets, or some other equally effective
safeguard.

When using electrically powered equipment

Turn off input power using the disconnect switch before working on the equipment.
Install grounding equipment and ground it in accordance with the National Electrical Code, all local codes
and the manufacturer's recommendations.

Property of Master Builders of Iowa / Construction Safety Specialists - 2002

Welders must place welding leads and other equipment so that it is clear of passageways, ladders, and
stairways so as not to create a trip/fall hazard or block egress.

When using engine powered equipment

Turn the engine off before troubleshooting and maintenance work unless the maintenance work
requires it to be running. Make sure you are trained and qualified to perform the work.
Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
Do not add the fuel near an open flame, welding arc or when the engine is running. Stop the
engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot
engine parts and igniting. Be cautious not to spill fuel when filling tank. If fuel is spilled, wipe it up and do
not start the engine until fumes have been eliminated.
Keep all guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
In some cases it may be necessary to remove safety guards to perform required maintenance.
Remove guards only if you trained and authorized and replace them when the maintenance requiring their
removal is complete. Always use the greatest care when working near moving parts.
Do not put your hands near the engine fan. Do not attempt to override the governor or idler by
pushing on the throttle control rods while the engine is running.
To prevent accidentally starting gasoline engines while turning the engine or welding generator during
maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
REMEMBER: ALWAYS HAVE INSTALLATION, OPERATION, MAINTENANCE AND REPAIR
WORK PERFORMED BY QUALIFIED PEOPLE.

****EVERYONE IS RESPONSIBLE FOR SAFETY IN THEIR AREA.****

****REPORT ALL SAFETY PROBLEMS IMMEDIATELY.****
ARC WELDING
Arc Welding, properly done, is a safe process, but a careless operator invites trouble. The equipment
carries high currents at significant voltages. The arc is very bright and hot. Sparks fly, fumes rise,
ultraviolet and infrared energy radiates, welding rods and some parts are hot. At times, compressed gases
may be used. Most arc welding and cutting processes, laser welding, and torch welding, cutting, and
brazing, or soldering produce quantities of radiation requiring precautionary measures. Some processes,
such as resistance welding and cold pressure welding, ordinarily produce negligible quantities of radiant
energy.
DEFINITION
Radiation is electromagnetic energy given off by the arc or flame that can injure eyes and burn the skin. An
operator sees visible light radiation. However, they do not see ultraviolet or infrared radiation. Radiation is
often silent and undetected, yet injury occurs.
EFFECTS OF RADIATION
The effects of radiation depend on the wavelength, intensity, and length of time one is exposed to the
radiant energy. Although a variety of effects is possible, the following two injuries are most common:
Skin burns.
Eye damage

Property of Master Builders of Iowa / Construction Safety Specialists - 2002

BURN PROTECTION
The welding arc is intense and visibly bright. Its radiation can damage eyes, penetrate lightweight clothing,
reflect from light-colored surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn, those
from gas-shielded arcs are more severe and painful.
Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the
arc when welding or observing open arc welding. Helmet shields and filter lens should conform to ANSI
Z87.1 standards. See the following page to consult the shade chart.
Use suitable clothing made from durable flame-resistant material to protect your skin and that of your
helpers from the arc rays.
Protect other nearby personnel with suitable non-flammable screening and/or warn them not to
watch the arc or expose themselves to the arc rays or to hot spatter or metal.
Wear protective clothing - leather gauntlet gloves, hat, and high safety-toe shoes. Button shirt
collar and pocket flaps or better yet no pockets, and wear cuffless trousers to avoid entry of sparks and slag.
Wear a helmet with safety goggles or glasses with side shields underneath, appropriate filter lenses or
plates (protected by clear cover glass). This is a MUST for welding or cutting, (and chipping) to protect the
eyes from radiant energy and flying metal. Replace cover glass when broken, pitted, or spattered.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and work pieces should never be handled without gloves.
Persons intending to perform hot work should not use flammable hair preparations.

Property of Master Builders of Iowa / Construction Safety Specialists - 2002

The following is a guide for the selection of the proper shade

numbers. The recommendations may be varied to suit the
individual's needs.
Shielded metal-arc welding
Gas-shielded arc welding (nonferrous)
Gas-shielded arc welding (ferrous)
Shielded metal-arc welding
Atomic hydrogen welding
Carbon arc welding
Soldering
Torch brazing
Light cutting, up to 1 inch
Medium cutting, 1 inch to 6 inches
Heavy cutting, 6 inches and over
Gas welding (light) up to 1/8 inch
Gas welding (medium) 1/8 inch to 1/2 inch
Gas welding (heavy) 1/2 inch and over
PLASMA ARC CUTTING (info from IOSH pamphlet)

10
11
12
12-14
10-14
14
2
3 or 4
3 or 4
4 or 5
5 or 6
4 or 5
5 or 6
6 or 8
8

Note: In gas welding or oxygen cutting where the torch produces a

high yellow light, it is desirable to use a filter or lens that absorbs
the yellow or sodium line in the visible light of the operation.

Property of Master Builders of Iowa / Construction Safety Specialists - 2002

FUMES AND GASES CAN BE DANGEROUS

Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and
gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc
to keep fumes and gases away from the breathing zone. When welding on galvanized, lead or cadmium
plated steel and other metals which produce toxic fumes, even greater care must be taken. There are
specialized respirator welding helmets for some of these more hazardous type fumes. As with any
respirator, you must be properly trained and authorized to use one.
Shielding gases used for arc welding can displace air and cause injury or death. Most shielding gases
are non-toxic, but as they are released they displace oxygen in your breathing air, causing dizziness,
unconsciousness, and possible death. Always use enough ventilation, especially in confined areas, to insure
breathing air is safe.
Read and understand the manufacturer's instructions for this equipment and the consumables to be
used, including the material safety data sheet (MSDS) and follow all safety practices.

WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION

If possible take the item to be a safe place to weld, cut or perform the hot work. If this is not feasible then
remove the fire hazards from the welding area. If this is not possible, cover the hazard to prevent the hot
work from starting a fire. Remember that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas or lower level floors. If this is possible have a Fire
Watch in place and have a fire extinguisher readily available.
Where compressed gases are to be used at the job site; special precautions should be used to
prevent hazardous situations.
When not welding, make certain no part of the electrode circuit is touching the work or ground.
Accidental contact can cause overheating and create a fire hazard. When welding is suspended for an
extended period of time for example breaks or over night the electrode must be removed for the electrode
holder.
No welding, cutting, or other hot work will be performed on used drums, barrels, tanks or other
containers until they have been cleaned so thoroughly as to make absolutely certain that there are no
flammable materials present or any substances such as greases, tars, acids, or other materials which when
subjected to heat might produce flammable or toxic vapors. Any pipelines or connections to the drum or
vessel must be disconnected or blanked. Read your MSDS.
NOTE: A good policy does not allow welding, cutting, or hot work to be performed on any used drums,
barrels, tanks or other containers unless the container is damaged and needs to be repaired to put it back
into service. And a qualified person performs the work.
Vent hollow castings or containers before heating, cutting or welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as
leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of positions or in confined places. Always wear safety glasses with side shields
when in a welding area.
Connect the work cable to the work as close to the welding area as practical. Work cables
connected to the building framework or other locations away from the welding area increase the
possibility of the welding current passing through lifting chains, crane cables or other alternate
circuits. This can create fire hazards or overheat lifting chains or cables until they fail. Also current going
through bearings may cause them to become pitted, or welded solid.

Property of Master Builders of Iowa / Construction Safety Specialists - 2002

WELDING IN WET AREAS

Precautions must be taken when welding in wet areas. The following steps must be taken to prevent
electrical shock.
Cables and welding units must be kept out of standing water.
Welding units should be kept dry.
All employees in the area must be notified by the welder and must keep a safe distance from the area where
welding is occurring.
When welding in damp locations the welder should wear non-conductive gloves under the welding gloves.

WELDING SAFETY
Any employee that uses a welder must assure a complete inspection of the welder is performed and that the
welder is safe for use. Make sure you have read and understand the instruction manual for the welder your
going to operate. Read all warnings and instructions on the equipment and nameplate. It is also important
to review the Material Safety Data Sheet for any consumables used during the welding operation.
1) The main power cord and leads must be visually inspected before use for external
defects (such as outer jacket or insulation damage) and for evidence of possible internal
damage (such as pinched or crushed outer jacket).
2) All welders are required to have rubber boots on the lead ends closest to the welder.
3) Machines that have become wet must be thoroughly dried before used.
4) The welder must assure that the power cord and lead ends are up and out of the way of any
vehicle traffic or any other device which could cause damage to the power cords or leads.
5) Before starting operations all connections to the machine must be checked to make certain
they are properly made.
6) If there is a defect or evidence of damage that might expose an employee to injury the defect or
damaged item must be removed from service, and no employee may use it until necessary
repairs and tests have been made to render the equipment safe.
7) Repairs to welding leads must be made with rubber and friction tape or equivalent means. Any
damaged lead beyond repair must be replaced. Electrical tape alone must not be used to repair damaged
leads.
8) Employees welding should not coil or loop cable leads around parts of their body. Electric current
flowing through any conductor causes localized Electric Magnetic Fields (EMF). Welding current
creates EMF around welding cables and the welding machine. EMF may interfere with some
pacemakers. Consult with your Doctor before using a welder.
9) Welding rod. When arc welding is to be suspended for any substantial period of time, (such
as during lunch or over night), all welding rods must be removed from the holders and the
holders carefully located so that accidental contact can not occur and the machine
disconnected from the power source.

Property of Master Builders of Iowa / Construction Safety Specialists - 2002

10) Check fire extinguisher for full, pin in place, plastic retainer, and no damage.
11) The Supervisor is responsible to ensure all welders are being inspected for safe operations.
12) All operators must inspect their welders before each use. Fill out the Welder Safety Inspection Sheet,
and have it with you while welding. This sheet must be turned into the Superintendent at the end of
the workday.
13) Make sure the settings are correct for the job youre about to perform.

SAFE HANDLING OF COMPRESSED GAS CYLINDERS

Use only compressed gas cylinders containing the correct shielding gas for the process used and
properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc.
should be suitable for the application and maintained in good condition.
Always keep cylinders secured in an upright position, with safety caps in place, in an area away form
combustibles and fuels, and safeguard them from damage, heat, and flames.
Cylinder location:
Keep cylindres away from areas where they may be struck or subjected to physical damage.
Oxygen and acetylene cylinders must be stored separately, at least 20 feet apart, or have a fire wall five feet
in height with a fire rating of at least one-half hour between them. Keep oxygen away from combustible
materials and fuels.
Never allow the electrode, electrode holder, or any other electrically "hot" parts to touch a cylinder. They
can produce short circuit arcs that may lead to a serious incident.
Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. Always
stand to the side when opening the valve.
Valve protection caps should always be in place and hand tight except when the cylinder is in use or
connected for use.
Read and follow the instructions on compressed gas cylinders and associated equipment.
Cylinders must be handled carefully to prevent leaks and damage to their walls, valves, or safety
devices.
ICC or DOT marking must be on each cylinder. It is an assurance of safety when the cylinder is
properly handled.
Identifying gas content. Use only cylinders with name of gas marked on them; do not rely on
color to identify gas content. Notify supplier if unmarked. NEVER DEFACE or alter the name,
number, or other markings on a cylinder. It is illegal and hazardous.
Empties: Keep valves closed, replace caps securely; mark MT; keep them separate from FULLS
and return promptly.
Prohibited use. Never use a cylinder or its contents for other than its intended use, NEVER as a
support or roller.

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Transport cylinders by strapping them to carts so they dont fall or bang into each other. Never drop or
roll a cylinder. With a crane, use a secure support such as a platform or cradle. Do NOT lift cylinders
off the ground by their valves or caps or by chains, slings, or magnets.
Do NOT expose cylinders to excessive heat, sparks, slag, and flame, etc. that may cause rupture.
Stuck valve. Do NOT use a hammer or metal wrench to open a cylinder valve that can not be
opened by hand. Notify your supplier.
Mixing gases. Never try to mix any gases in a cylinder.
Never refill any cylinder yourself. Have the professionals do it.
Cylinder fittings should never be modified or exchanged.

CYLINDERS MAY EXPLODE IF DAMAGED, OR HANDLED IMPROPERLY

Compressed Gas Cylinder Explodes

During a filling operation where an employee of a compressed gas distributor was filling a nitrogen/CO
cylinder, the cylinder exploded, sending shards of shrapnel throughout the facility. The employee lost both
legs in the explosion - some of the shrapnel was close to 1' in diameter.
OSHA has conducted forensic testing of the cylinder material, they have determined that the facility
followed all prescribed procedures, and that all appropriate hydrostatic testing of the cylinder had been
performed. No citations were issued.
At issue in the case, is that the cylinder was US Army issue, and, according to serial number research, was
originally manufactured in 1919! It is interesting to note that NFPA requirement mandate the retirement of
LP tanks after 12 years, but there are no standards governing the retirement of other types of compressed
gas cylinders
It is recommended that you take an inventory of your cylinders, and note the testing stamps (the one above
had stamps all the way back to 1919, every five years like clockwork). A good idea would be to contact
your distributor and work out a replacement plan for older cylinders, based on a mutual understanding of
the risks involved.
Hose's
Prohibited use. Never use hose other than that designed for the specified gas. A general hose
identification rule is: red for fuel gas, green for oxygen, and black for inert gases.
No copper tubing splices. Use only standard brass fittings to splice hose.
Avoid long runs to prevent kinks and abuse. Suspend the hose off ground to keep it from being run
over, stepped on, or otherwise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and loose connections. Immerse pressured hose in water; bubbles
indicate leaks.

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Repair leaky or worn hose by cutting the area out and splicing. Use ferrules or clamps designed for the
hose (not ordinary wire or other substitute as a binding to connect hoses to fittings). Do NOT use tape.
PRESSURIZING STEPS:
1.
Before attaching regulator to outlet of cylinder valve, open cylinder valve for a few seconds,
allowing gas to force out any possible foreign matter.
2.

Attach regulator to cylinder valve and tighten inlet nut securely with regulator wrench. The
regulator outlet (or hose) connections may be identified by right hand threads for oxygen and left
hand threads (with grooved hex on nut or shank) for fuel gas.
Before opening cylinder valve, turn adjusting screw to the left until no spring tension is felt.
(Never open cylinder valve until spring tension on adjusting screw has been released in this
manner).

3.

Open cylinder valve slowly. DO NOT STAND IN FRONT OF OR BEHIND REGULATOR

WHILE OPENING THE CYLINDER VALVE. When gauge is
pressurized (gauge reaches regulator maximum) leave cylinder valve in following position:
- For oxygen, and inert gases, open fully to seal stern against possible leak. For fuel gas, open to
less than one turn to permit quick emergency shutoff.
- Check for leaks on first pressurization and regularly thereafter. Remove leaky or defective
equipment from service immediately and repair them only if recommended in equipment
instruction manual. Send others for repair to manufacturer's

4.

Turn adjusting screw to the right until the low pressure gauge registers the desired working
pressure.

CAUTION: Never turn adjusting screw to the left while the low pressure gauge shows pressure, unless the
outlet leading from the regulator is open and gas is escaping. Never use oil or petroleum base grease on
regulator, inlet connection or cylinder valve. When leaving Equipment Unattended Close gas supply at
source and drain gas from hoses.

HOT WORK PERMITS

BACKGROUND
A hot work permit is issued as a documented checklist / procedure to ensure that the area you are going to
be doing the hot work in is completely safe from having any fire hazard. The program also assures that all
potential fire hazards have been removed or covered. Other wise the hot work can not be performed! Hot
work includes activities such as; welding, cutting with a torch or plasma cutter, cutting or grinding with a
grinder, use for heat guns or other sources of heat that could support fire. See Appendix C for the training
outline and employee certification of training.

HOT WORK MAY NEVER BE PERFORMED:

a) In the presence of explosive atmospheres (mixtures of flammable gases, vapors, liquids,
or dusts with air), or explosive atmospheres that may develop inside uncleaned or
improperly prepared tanks or equipment which have previously contained such materials,
may develop in areas with an accumulation of combustible dusts.

or that

b) In areas near the storage of large quantities of exposed, readily ignitable materials.

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PROCEDURES:
INITIATING A HOT WORK PERMIT
The first step in the hot work permit procedure is the identification of the need for a hot work permit. Any
employee may make the request for a hot work permit if they feel that an operation presents an unusual
hazard that requires special safety precautions. Remember that a hot work permit is required for any
operation that could cause a source of ignition in a hazardous location. The request for a hot work permit
should be made to the Jobsite Supervisor on the day that the hot work is to be performed.
ISSUING A HOT WORK PERMIT
The Jobsite Supervisor has the responsibility to fill out the hot work permit once a request for a hot work
permit is made. The permit must be filled out before the hot work is started. The supervisor must inspect
the work area before filling out the hot work permit.
The hot work permit must show the date and time that the work will be performed, the location, a short
description of the work to be performed, the name of the cutter/welder, and the name of the fire watch (if
one is required). The hot work permit is valid only for the job and the time listed on the permit. The hot
work permit will be valid for no longer than the work shift for the day of request.
The next step is for the Jobsite Supervisor to review the list of hot work precautions with the cutter/welder
and with the fire watch. These precautions are summarized on the hot work permit. Note that the hot work
precautions outlined on the permit are minimum precautions; the Jobsite Supervisor or owner may take
additional measures for safety of personnel and property.
After the Jobsite Supervisor is assured that all necessary hot work precautions have been taken, they must
initial each item on the permit, sign the permit, and then issue it to the cutter/welder. The cutter/welder and
the fire watch then signs the permit indicating that they have reviewed the hot work precautions with the
supervisor and understand their responsibilities. The Jobsite Supervisor will keep a copy of the permit and
the cutter/welder will post the original at the job site on or near the equipment where the work is to be
performed as a warning to other workers of the hot work operation. The permit should remain in this place
until the hot work is completed.
PERFORMING HOT WORK
The cutter/welder is responsible for conducting the hot work within the authorized parameters and time
limit set by the permit. Hot work may continue as long as conditions remain safe and no new hazards have
been introduced.
The following precautions should be taken when performing any hot work operations:

Perform hot work in a fire safe area except when the job cannot be moved.

Use only equipment that is in good condition. Valves, regulators, hoses cables and torches should be
thoroughly checked before each use. See the Equipment Safety Check program found in
Appendix B.

Do not perform portable welding, cutting, or other hot work operation in a building where
sprinklers are out of service.
Move combustibles at least 35 feet from hot work operations. If combustibles cannot be moved,
they should be protected by metal guards or by flameproof curtains or covers rather than by
ordinary tarpaulins.

Do not perform hot work in or on any vessels containing flammable, combustible materials, until they have
been disconnected or blanked, completely cleaned out, and purged.

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Check the atmosphere for combustible gases or vapors, where necessary, using reliable detection
equipment. If there is a chance of gas release during hot work operations, continuous monitoring
must be performed. (Refer to our companies Confined Space Program).

Ensure that a fire extinguisher is readily available for instant use in the area.

Do not perform hot work until surrounding floors have been swept clean and if combustible, wet
down with water or covered with flameproof material.

Do not perform hot work until all wall and floor openings within 35 feet of the operations have
been tightly covered and or protected with flame proof material.

Do not perform hot work until a fire watch has been assigned to watch for dangerous sparks in the
area and on floors above and below the operation.

Secure gas cutting and welding cylinders so they will not be damaged and replace protective caps
(and closed gas supply valves) on all cylinders not actually in use.

Carefully and securely connect the ground clamp when using electrical arc welding equipment.
Since improperly made ground can be a source of ignition, the ground clamp should be connected
as close to the work as possible so that it may easily be observed.

Use portable stands to elevate welding hose or cable off floor areas to avoid damage to the hose or
cable.

Ensure adequate ventilation is maintained during hot work operations to assure that employees are
not exposed to harmful fumes. This may include positioning of an exhaust blower close to the
point of the exhaust fumes. Respiratory protection may also be considered.

Remove all electrodes from the holders, carefully locate them so that accidental contact cannot
occur, and disconnect the welding machine from the power source if hot work is to be suspended
for any substantial period (e.g., lunch or overnight).

The fire watch shares the responsibility for fire/safety with the cutter/welder. The fire watch should
maintain constant watch during the operation (including lunch and breaks) to watch for stray sparks,
ignition sources, or other fire hazards. The fire watch must be trained in the use of a fire fighting
equipment, stages of fire, and must have the equipment readily available. He/she should be familiar with
the job site and also know how to sound the alarm. Its the fire watch's responsibility to attempt to
extinguish any fire that might occur, as long as the equipment has the capacity available. If the fire watch
feels they are in danger because of the fire stage then they must sound the alarm and evacuate.
The Jobsite Supervisor should inspect the work area during the hot work operations to ensure that the
conditions of the hot work permit are being fulfilled.

COMPLETING THE HOT WORK PERMIT PROCEDURE

When the hot work is completed, the fire watch must remain for at least 30 minutes, carefully inspecting the
work area and adjacent areas for the possibility of any smoldering fires. This inspection extends to floors
above and below the work area and to adjacent rooms.
Barring any fires, the fire watch removes the hot work permit. The fire watch then signs the permit, writes
the completed time and then returns the permit to the Jobsite Supervisor.

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The Jobsite Supervisor must return to the area one hour later; smoldering fires may take that long to become
apparent. After this final inspection, the Jobsite Supervisor will sign the hot work permit, write the time of
the final inspection, and send the original to the safety office to be filed.
PERSONNEL RESPONSIBILITIES
The following describes the various persons/departments who may be involved in the hot work permit
procedure, and summarizes their responsibilities.
Originator
Identifies the need for a hot work permit;
Submits hot work permit request to the Jobsite Supervisor;
Works with other trades, as assigned, during the implementation of the hot work permit procedure.
Jobsite Supervisor
Has overall responsibility for ensuring that the hot work permit procedure is followed.
Inspects the work area before filling out the hot work permit;
Makes a determination as to whether a fire watch is necessary;
Completes the hot work permit after completing inspection of work area;
Reviews the list of hot work precautions with the cutter/welder and the fire watch;
Specifies any additional precautions that may be necessary for the hot work permit;
Signs the hot work permit and issue it to the cutter/welder when assured that all necessary hot work
precautions have been taken;
Inspects the work area during the hot work operations to ensure that the conditions of the hot work
permit are being fulfilled;
Returns to the hot work area (or direct cutter/welder or fire watch to return to the area) one hour
later to inspect for smoldering fires; and,
Signs the hot work permit after the final site inspection has been completed and sends the original
to the safety office to be filed.

Cutter/Welder
Reviews the list of hot work precautions with the Jobsite Supervisor and signs the permit;
Affixes the hot work permit and precautions to a visible place in the work area;
Conducts the hot work operations within the authorized parameters and time limit set by the hot
work permit;
Stops hot work operations if any new hazards are introduced to the process;
May remain in the area for 30 minutes after work is completed, carefully inspecting the work area
and adjacent areas for any smoldering fires;

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May sign and return the hot work permit to the Jobsite Supervisor after the 30 minute inspection;
and,
May return to the hot work area one hour later to inspect for smoldering fires if instructed to do so
by the Jobsite Supervisor.
Fire Watch
Reviews the list of hot work precautions with the Jobsite Supervisor and signs the permit;
Maintains a constant watch during the hot work operations (including lunch and breaks) to watch
for stray sparks, ignition sources, or other fire hazards;
Ensures that fire-extinguishing equipment is readily available for instant use in the area;
Stops hot work operations if any new hazards are introduced to the process;
Extinguishes any fires if they occur as long as they are within the capacity of the equipment
available, or otherwise sounds the fire alarm;
Remains in the area for at least 30 minutes after work is completed, carefully inspecting the work
area and adjacent areas for any smoldering fires; and,
May return to hot work area one hour later to inspect for smoldering fires if instructed to do so by
the Jobsite Supervisor.
DOCUMENT MANAGEMENT:
The only document associated with hot work permit procedures is the permit itself, found in
Appendix A of this program. Documentation should be managed as follows:
Hot Work Permit
The Jobsite Supervisor retains the supply of blank permits. Upon request they fill out the permit
and sign it to authorize the work. The permit is then signed by the cutter/welder and one copy of
both sides of the permit is made. The Jobsite Supervisor retains the copy and cutter/welder takes
the original to the job site where it is posted. Upon successful completion of the work the
Supervisor or Fire Watch (if needed) signs the permit. The completed permit is then filed as
follows:
Original - Sent to the Safety Director
Copy - Filed at the job site
1.

When a Hot Work Permit is required, a signed permit must be issued before cutting, welding, or
other hot work is permitted, the area must be inspected by the individual responsible for
authorizing the hot work operations. This individual must designate precautions to be followed in
granting the authorization.

2.

If automatic sprinklers are in the area, check that they are in service.

3.

Floors must be swept clear. Combustible floors must be wet down, or covered with other fire
retardant material. Where floors have been wet down, personnel operating arc welding or other
cutting equipment must be protected from possible shock.

4.

Remove flammable liquids and clean up oily deposits.

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5.

Move combustibles to a minimum distance of 35 feet. If not practicable, cover the storage area
with fire -resistant drop cloths or isolate the welding with a temporary fire resistant enclosure.

6.

Ducts and conveyor systems that might carry sparks to distant combustibles must be
suitably protected or shut down.

7.

Combustible walls. Where cutting or welding is done near walls, partitions, ceiling or roof of
combustible construction, fire-resistant shields or guards must be provided to prevent ignition.

8.

Noncombustible walls. If welding is to be done on a metal wall, partition, ceiling or roof,

precautions must be taken to prevent ignition of combustibles on the other side, due to
conduction or radiation, preferably by relocating combustibles. Where combustibles are not
relocated, a fire watch on the opposite side from the work must be provided.

9.

Combustible cover. Welding must not be attempted on a metal partition, wall, ceiling or roof
having a combustible covering.

10.

Pipes. Cutting or welding on pipes or other metal in contact with combustible walls, partitions,
ceilings or roofs must not be undertaken if the work is close enough to cause ignition by
conduction.

11.

Station a Fire Watch. A Fire Watch must be in place whenever hot work is performed in locations
where other than a minor fire might develop, or any of the following conditions exist:
Combustible material is closer than 35 feet from the point of operation.
Combustible materials are more than 35 feet away but are easily ignited by sparks.
Wall or floor openings within a 35-foot radius expose combustible materials in adjacent areas
including concealed spaces in walls or floors.
Combustible materials are adjacent to the opposite side of metal partitions, walls, ceilings, or
roofs and are likely to be ignited by conduction or radiation.
The Fire Watch must have fire-extinguishing equipment readily available and be trained in its
use and limitations. They must be familiar in the procedures for sounding the alarm in the
event of a fire. The Fire Watch must watch for fires in all exposed areas and steel members,
pipes etc. that can transmit heat to walls, ceilings, or combustibles. The designated fire
watch's only responsibility will be to watch for fires!

12.

When the work is completed, the Fire Watch must check adjoining areas and/or floors (above and
below) for smoldering fires that might have started unnoticed. The Fire Watch must maintain a
watch for 30 minutes after completion of welding or cutting operations to detect and extinguish
possible smoldering fires.

13.

The Jobsite Supervisor must return to the scene within one hour after the work has been done to
sign and retrieve the permit and to check the area to assure no fires have started.

14.

Restrictions. If the above stated in this section cannot be followed, then welding, cutting, or
other hot work must not be performed.

15.

Permits are located in the job trailer. Ask your supervisor when you need one.

FIRE EXTINGUISHERS
There are four basic types of fire extinguishers we may use. These are:
Type A - ordinary combustibles. Those consisting of ordinary combustible materials such as
wood, cloth, and paper.

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Type B - Flammable Liquids. Those involving flammable liquids, gases and greases.
Type C - Electrical Equipment. Those involving energized electrical equipment.
Type D - Combustible Metals. Fires which occur in combustible metals such as magnesium,
titanium, zirconium and sodium.
The most commonly used fire extinguisher available is the ABC type, which will cover types A, B, C fires.
In some areas where electrical fires are the only concern, such as electrical rooms B, C type fire
extinguishers may be used. This type is good for both class B and class C fires. (liquids, greases, and
electrical) These can not be used on type A fires (ordinary combustibles).
Anytime there is a possibility that you might have to use a fire extinguisher, such as doing hot work; you
have to do a pre-check on the fire extinguisher. You need to check the following things on the fire
extinguisher;
1) Clean and in good condition.
2) Pin sealed to the handle with plastic retainer in place. If this has been broken get it replaced. If
the plastic retainer is broken on a B type fire extinguisher remove the fire extinguisher from
service and replace it with a known charged one.
3) Check the pressure gauge to make sure it is full and not damaged.
4) See that the inspection tag is on the fire extinguisher and that it has not expired.
Anyone who is expected to use a fire extinguisher must be properly trained in its use, the stages of fire and
how to report a fire. Remember the simple acronym P.A.S.S. Pull the pin; Aim at the base of the fire,
Squeeze the handle, Sweep side to side.

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Confirmation of Understanding
Hot Work
Name: ______________________________
S.S. #: ______________________________
Date ________________________________

1. What is a Hot Work permit? ______________________________________

_____________________________________________________________
2. When is a Hot Work Permit required?_______________________________
3. What are 3 things that can be done in the area immediately around the work
to reduce the potential for fire?
a) ________________________________________________________
b) ________________________________________________________
c) ________________________________________________________
4.

Why does there need to be a second person who is the fire watch?
__________________________________________________________
__________________________________________________________
__________________________________________________________

5.

How long after the hot work is done, does the fire watch need to stay at the
scene and why?______________________________________________
___________________________________________________________
___________________________________________________________

6.

a. Who signs the hot work permit? _____________________________

__________________________________________________________
__________________________________________________________
b. Why does the above person/persons need to sign the permit?_______
__________________________________________________________
__________________________________________________________

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7.

T or F

A fire watch can be a co-worker that is working nearby.

8.

When is the permit removed from the area of hot work?

__________________________________________________________

9. What four things need to be checked on a fire extinguisher to make sure it is

ready for service?
1)
2)
3)
4)
10. When putting out a fire what type of motion are you using?

11. Explain P.A.S.S. when dealing with fire extinguishers.

P.
A.
S.
S.
12. Name the four types of fire extinguishers and their use.
1. ________________________________________________________________
2. ________________________________________________________________
3. ________________________________________________________________
4. ________________________________________________________________
13.

What are two things you must do to prevent breathing welding

fumes? ____________________________________________________
__________________________________________________________

14.

What should be done if bad insulation is found on a cable lead or power

cord of a welder? ___________________________________________
__________________________________________________________

15.

What is the maximum pressure acetylene can be used in a free state?

_____________________________________________________P.S.I.

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16.

What are three requirements for storage of oxygen and acetylene?

__________________________________________________________
__________________________________________________________

17.

When should you purge the lines of an oxygen/acetylene rig?

__________________________________________________________
__________________________________________________________

18.

What are two ways to avoid electrical shock while welding?

__________________________________________________________
__________________________________________________________

19.

List two requirements for the transportation of compressed gas cylinders.

__________________________________________________________
__________________________________________________________

20.

Explain two different accidents that could happen from the misuse of
acetylene.__________________________________________________
__________________________________________________________
__________________________________________________________

21.

Explain two accidents that could happen from electric arc welding.
__________________________________________________________
__________________________________________________________
__________________________________________________________

22.

What should be done if an item on your Welder Safety Inspection Sheet

checks out bad? ____________________________________________
__________________________________________________________
__________________________________________________________

23.

How often do you have to do your welder's safety checklist?

__________________________________________________________

24.

What are the disciplinary actions for not performing the Welder Safety
Inspection? ________________________________________________
__________________________________________________________

25.

With the regulator hooked up, where should you not stand when turning
on the cylinders valve? _____________________________________
_________________________________________________________

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26.

When lighting a torch what should be lit first?____________________

_________________________________________________________

27.

If the cylinder valve is stuck shut what should you do?_____________

_________________________________________________________

28.

What color is the oxygen hose? _______________________________

What color is the acetylene hose? _____________________________
What color is the inert gas hose?

___________________________

29.

Before attaching the regulator to the outlet of a cylinder valve what

must be done?_____________________________________________
________________________________________________________

30.

When must cylinder caps be in place? __________________________

_________________________________________________________

31.

How must cylinders be secured? ______________________________

________________________________________________________

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Confirmation of Understanding
Hot Work
ANSWER KEY

1.

What is a Hot Work permit?

Documented check list/procedure to make sure there are no fire hazards
present

2.

When is a Hot Work Permit required?

Anytime you do any Hot Work and your not in a designated area for that
work.

3.

What are 3 things that can be done in the area immediately around the work
to reduce the potential for fire?
Remove combustibles, sweep floor back 35, shut down conveyors,
ductwork, cover combustibles, wet floors, have fire watch, follow hot work
permit.

4.

Why does there need to be a second person who is the fire watch?
The person doing the hot work might be to busy working to notice a small
fire.

5.

How long after the hot work is done, does the fire watch need to stay at the
scene and why?
30 min, to make sure no smoldering fire start up.

6.

a. Who signs the hot work permit?

The hot worker, The fire watch, and the jobsite supervisor

b. Why do the above person/persons need to sign the permit?

To hold them accountable for the hot work.

7.
8.

T or F

A fire watch can be a co-worker that is working nearby.

When is the permit removed from the area of hot work?

1 hr after the hot work is done the jobsite supervisor goes and retrieves
the permit. Making sure no fire have started up.

9.

What four things need to be checked on a fire extinguisher to make sure it is

ready for service?
1) Clean and good condition
2) Pin sealed to the handle
3) Check gauge for fullness
4) The monthly tag is on it and has been punched for the month
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Property of Master Builders of Iowa / Construction Safety Specialists - 2002

10. When putting out a fire what type of motion are you using?
Sweeping motion side to side at the base of the fire.

11. Explain P.A.S.S. when dealing with fire extinguishers.

P. Pull the pin
A. Aim the nozzle
S. Squeeze the handle
S. Sweep side to side
12. Name the four types of fire extinguishers and their use.
1.Type A - Combustibles
2.Type B - Flammable liquids
3.Type C - Electrical
4.Type D Combustible Metals
13.

What are two things you must do to prevent breathing welding

fumes?
Head out of the fumes, and ventilation, use respirator if qualified

14.

What should be done if bad insulation is found on a cable lead or power

cord of a welder?
Tagged out, the cable or power cord replaced or properly repaired

15.

What is the maximum pressure acetylene can be used in a free state?

15 psi

16.

What are three requirements for storage of oxygen and acetylene?

Caps on, Chained in storage rack, upright, separate

17.

When should you purge the lines of an oxygen/acetylene rig?

Before each use of the rig.

18.

What are two ways to avoid electrical shock while welding?

Gloves and clothing dry, rubber gloves under gloves, Dont weld in
standing water, dont become path between the ground and work cables.

19.

List two requirements for the transportation of compressed gas cylinders.

Chained to a cart, in cart or cradle designed for carrying compressed
gases, upright, safety caps on etc

20.

Explain two different accidents that could happen from the misuse of
acetylene.
Explosion, frost bite, affixation, burns
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Property of Master Builders of Iowa / Construction Safety Specialists - 2002

21.

Explain two accidents that could happen from electric arc welding.
Shock, burns, eye burns, fume poisoning, fire

22.

23.

What should be done if an item on your Welder Safety Inspection Sheet

checks out bad?
Welder tagged out of service, and repaired.
How often do you have to do your welder's safety checklist?
Each time you use the welder.

24.

What are the disciplinary actions for not performing the Welder Safety
Inspection?
Discipline up to and including discharge.

25.

With the regulator hooked up, where should you not stand when turning on
the cylinders valve?
In front or behind the regulator

26.

When lighting a torch what should be lit first?

Acetylene

27.

If the cylinder valve is stuck shut what should you do?

Tag it out of service and return it to the supplier to be fixed.

28.

What color is the oxygen hose?

Green

What color is the acetylene hose? Red

What color is the inert gas hose? Black
29.

Before attaching the regulator to the outlet of a cylinder valve what must be
done?
Check to make sure there is no grease or oil around outlet, then crack the
valve for a moment to blow out foreign material.

30.

When must cylinder caps be in place?

Anytime they are not hooked up to be used.

31.

How must cylinders be secured?

By a chain or strap to a cart or a fixed support.

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APPENDIX A
HOT WORK PERMIT

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HOT WORK IN
PROGRESS
WATCH FOR FIRE!
IN CASE OF AN
EMERGENCY:
CALL: _________________________
AT:____________________________

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HOT WORK PERMIT

SAFEGUARD CHECKLIST
___ Hot Work Equipment must be in safe working
condition and operators trained in its use.
___ Standby Fire Fighting Equipment must be
available.
___ Combustible materials shall be swept clean within
35 ft. of work.
___ Eliminate explosive atmosphere (gaseous
flammables in area/confined space)
___ Remove Combustibles where practical,
otherwise, protect with flameproof covers.
___ Combustible constructed walls (Kemlite Included)
shall be covered.
___ Remove combustibles from the back side of the
wall.
___ Cover all floor and wall openings.
___ Are the Oxy/Acet tanks outside the confined
space.
___ Mechanical ventilation provided to remove toxic
gases or vfapors from spaces.
___ Shutdown ducts conveyor systems that may
convey sparks to distant combustibles.
___ Maintain a fire watch for 30 minutes after
completion of work.
___ Fire watchers shall have fire extinguishing
equipment and be trained in usage.
___ Fire watchers shall watch for fires in all exposed
areas and steel member, pipes etc. that can transmit
heat to walls, celings, or combustibles.
___ Fire Watchers will be trained in sounding alarm.
___ Other Safeguards taken:_________________
____________________________________________
____________________________________________
____________________________________________
____________________________________________
____________________________________________
____________________________________________
____________________________________________
____________________________________________
________

INSTRUCTIONS
1.) To person authorized to issue HOT WORK
PERMITS.
a.) While visiting the jobsite, complete the checklist on
the left.
b.) Next, fill in the portion below.
c.) Retain PART 1 (this must be kept until the work is
completed)
d.) Issue PART 2 to person doing the job.
____________________________________________
_
HOT WORK BEING DONE BY:
____ Employee
____ Contractor
_______________________________
Date:
________________________________________
Job / W.O. Number:
____________________________
Location:
_____________________________________
Object that Hot Work is to be Performed On:
_________
____________________________________________
_
Name of Person
Doing Hot Work:
________________________________
I Have Examined The Job Site Listed Above and The
Safeguards on the Checklist Have Been Taken To
Prevent a Fire.
Signed (Authorized Supervisor)
____________________________________________
_
Permit
Expires

Date:

Time:

am
pm

Property of Master Builders of Iowa / Construction Safety Specialists - 2002

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Property of Master Builders of Iowa / Construction Safety Specialists - 2002

APPENDIX B
EQUIPMENT
SAFETY CHECK

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OXY / ACETYLENE WELDER SAFETY CHECKLIST

If any defects or evidence of damage is noted that might expose an employee to injury the equipment will be removed from service.
Before the equipment is used, this checklist must be completed. A copy turned into the Jobsite Supervisor by the end of the shift.

TANKS / CYLINDERS
All cylinder / tank valves should be inspected to ensure that they are free of dirt, rust, lubricant, oil or
grease. Valves should be cracked to clear the valve of any particles of dirt or rust. Inspect the label to
ensure that the proper types of gases are being used. Cylinders should be secure upright in the stands.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
REGULATORS
Ensure that the proper regulator is being used for the proper gas. Regulators should be mounted on cylinder
so that the readings of the gauges are visible to the operator. Gauges should be inspected to ensure that they
are working properly, lenses shouldnt be cracked or broke etc.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
HOSES / GAS LINES
All hoses / gas lines should be inspected for cracks, breaks and leaks around fittings etc. Ensure that
backflow preventors are in place.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
TORCH HEAD
Inspect valves, fittings and tips for leaks. O-Rings should be inspected and replaced if worn. Torch head
should be free of greases, oils and lubricants just as the valves should be.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
Welder #

Date:

Inspector

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HELIARC SAFETY CHECKLIST

If any defects or evidence of damage is noted that might expose an employee to injury the equipment will be removed from service.
Before the equipment is used, this checklist must be completed. A copy turned into the Jobsite Supervisor by the end of the shift.

TANKS / CYLINDERS
All cylinder / tank valves should be inspected to ensure that they are free of dirt, rust, lubricant, oil or
grease. Valves should be cracked to clear the valve of any particles of dirt or dust. Inspect label to
ensure that the proper type of gas is being used. Cylinders should be secured upright in the stands.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
REGULATOR
Ensure that the proper regulator is being used. Regulators should be mounted on cylinder so that the
readings of the gauges are visible to the operator. Gauges should be inspected to ensure that they are
working properly, lenses shouldnt be cracked or broke etc.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
HOSES / GAS LINES
Hose / gas line should be inspected for cracks, breaks and leaks around fittings etc.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
LEAD / CABLE
Lead / cable should be inspected for cuts, breaks and cracks.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
TORCH HEAD
Inspect valve for leaks. O-Rings should be inspected and replaced if worn. Rubber insulation on electrode
housing should be inspected for cracks and tears etc.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
Welder #

Date:

Inspector:

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PLASMA CUTTERS SAFETY CHECKLIST

If any defects or evidence of damage is noted that might expose an employee to injury the equipment will be removed from service.
Before the equipment is used, this checklist must be completed. A copy turned into the Jobsite Supervisor by the end of the shift.

AIR REGULATOR / GAUGE

Inspect regulator and air gauge ensuring they are operating properly. Glass dome on regulator / gauge
should be in good condition, not cracked or broken.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
HOSE
Air hose should be inspected for cracks, breaks and leaks around fittings.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
LEADS / CABLES
Leads / cables and power cord should be inspected for cuts, breaks, cracks or exposed wires.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
TORCH HEAD
Inspect torch head for loose or exposed wires and hose fittings. Torch head casing should be clean and in
good condition.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
GROUNDING
All ground leads and connections should be strong and electrically adequate for the required current.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
Plasma Cutter #

Date:

Inspector:

ARC WELDER SAFETY CHECKLIST

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Property of Master Builders of Iowa / Construction Safety Specialists - 2002

If any defects or evidence of damage is noted that might expose an employee to injury the equipment will be removed from service.
Before the equipment is used, this checklist must be completed. A copy turned into the Jobsite Supervisor by the end of the shift.

WELDING LEADS / CABLES

All leads / cables and terminal covers should be inspected for cuts, breaks and cracks. All defects must be
repaired or replaced. There must be no defects within 10 feet of the stinger / electrode holder. All repairs
to cables and leads must be done by approved methods.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
STINGER / ELECTRODE HOLDER
The stinger / electrode holder should be inspected for cracked or broken porcelain. If any defects are found
the stinger / electrode holder must be replaced.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
GROUNDING
All ground connections shall be inspected to determine that they are mechanically strong and electrically
adequate for the required current.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
SWITCHES / MISCELLANEOUS
All switches and dials shall be inspected to ensure proper functioning and the welder frame and housing
should be inspected to ensure that it is in good condition.
COMMENTS:_________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
Welder #

Date:

Inspector

MIG / WIRE FEED WELDERS SAFETY CHECKLIST

If any defects or evidence of damage is noted that might expose an employee to injury the equipment will be removed from service.
Before the equipment is used, this checklist must be completed. A copy turned into the Jobsite Supervisor by the end of the shift.

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TANK / CYLINDER
Inspect cylinder valve ensuring that it is free of dirt, rust, lubricant, oil or grease. Valve should be cracked
to clear the valve of any particles of dirt or dust. Inspect label to ensure proper gas is being used. Cylinder
should be upright and secure in stand.
COMMENTS:________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
REGULATOR
Ensure proper regulator is being used for the proper gas. The operator of the welder should mount
regulator on cylinder to allow readings to be visible. Inspect gauges ensuring that they are operating
correctly, lenses should be in good condition not cracked or broken.
COMMENTS:________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
HOSE / GAS LINE
Inspect hose / gas line for cracks, breaks and leaks around fittings.
COMMENTS:________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
LEADS / CABLES
Inspect leads / cables and power cord for cuts, breaks, cracks or exposed wires.
COMMENTS:________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
TORCH HEAD
Inspect torch head for loose leads, wires and hose fittings. Torch head casing / housing should be inspected
for cracks and breaks.
COMMENTS:_______________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
GROUNDING
Ground clamp shall be inspected to determine that they are strong and electrically adequate for the required
current.
COMMENTS:________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
Welder #

Date:

Inspector:

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Property of Master Builders of Iowa / Construction Safety Specialists - 2002

APPENDIX C
HOT WORK PERMIT
TRAINING OUTLINE

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Property of Master Builders of Iowa / Construction Safety Specialists - 2002

HOT WORK PERMIT TRAINING OUTLINE

1. Review Definitions
2. Review operations needing a hot work permit.
a) Review the types of operations that a hot work permit is required
3. Review the hot work permit
a) Cover each section of the hot work permit
b) Have employee complete a hot work permit
4. Review the hot work permit procedure
a) Initiating a hot work permit
b) Issuing a hot work permit
c) Performing hot work
d) Completing the hot work permit
5. Review responsibilities
a) Originator responsibilities
b) Site Supervisor responsibilities
c) Cutter or welder responsibilities
d) Fire watch responsibilities
6. Review document management section of the program
a) Management of the hotwork permit
b) Location of permits
c) Posting of permits
d) Retention of permits
7. Review the equipment preventive maintenance safety checklists
a) Oxy/Acetylene checklist
b) Heliarc checklist
c) Plasma cutter checklist
d) Arc welder checklist
e) Mig/Wire feed welder checklist
8. Complete employee training certification and confirmation of understanding

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Property of Master Builders of Iowa / Construction Safety Specialists - 2002

NAME:____________________________________
DATE:__________________________

HOT WORK PERMIT PROGRAM

CERTIFICATION OF TRAINING IN THE HOT WORK PERMIT PROGRAM
This is to certify that I have received training and instructions in the Companies Hot
Work Permit Program. I have learned about specific hazards, hot work operations and
procedures that will enable me to actively participate in this program. I have checked the
topics that have been covered and I understand each topic:
(
(
(
(
(
(
(
(
(
(
(

) Definitions
) Safety precautions for hot work
) Equipment Safety Checklist
) Fire extinguishers; types, use and care
) Operations that require a hot work permit
) Each section of the hot work permit
) Hot work permit procedure
) Responsibilities in program
) Document management
) Equipment Preventive Maintenance Program
) Confirmation of understanding (test)

________________________________
INSTRUCTOR SIGNATURE
_________________________
DATE

__________________________________
EMPLOYEE SIGNATURE
_________________________
DATE

38