Fire Safety During Hot Work Operations
The Problem
Hot work operations — such as welding, cutting, grinding, and brazing — are common tasks on many sites, but they’re also one of the leading causes of fires and explosions. These activities produce sparks, heat, and molten material, which can ignite nearby combustible materials and lead to serious injury, property damage, or fatalities. Today, we’ll identify these hazards and review fire safety procedures aligned with Canadian Centre for Occupational Health and Safety (CCOHS) best practice guidance.
Identify the Hazards
Safety Practices and Preventative Measures
Authorization and Pre-Work Inspections
- Obtain a Hot Work Permit before starting any work outside designated hot work zones.
- Conduct a hazard inspection to identify combustible materials or flammable vapours.
- Where possible, perform hot work in designated fire-resistant areas.
Fire Protection Equipment
- Ensure that fire extinguishers, water hoses, or buckets of sand are on hand and operational.
- Use the correct extinguisher type (e.g., Class A, B, or C).
- Train all workers and fire watchers in extinguisher use and emergency procedures.
Handling Combustible Materials
- Remove combustible items within a 10-metre radius of the hot work area.
- Protect immovable combustibles using fire blankets, welding curtains, or fire shields.
- Keep the work area clean — remove flammable debris and protect floors with damp sand or fire-resistant sheeting.
Preventing Fire Spread
- Seal gaps or cracks in walls, floors, and ceilings to stop sparks escaping.
- Shut down ventilation ducts or conveyors that may carry sparks elsewhere.
- Assign a fire watch to monitor heat transfer through metal walls or structures to adjacent spaces.
Fire Watch Requirements
- Assign a trained fire watch when:
- Combustibles are present
- Sparks may spread
- Heat transfer through structures is possible
- Fire watchers must:
- Be trained in fire extinguisher use
- Know emergency procedures and alarm locations
- Stay in the area for at least 30 minutes post-work to check for smouldering fires
Special Considerations for Equipment and Spaces
- Clean tanks, drums, or pipes thoroughly to remove flammable residues before beginning hot work.
- Ensure proper ventilation in confined spaces and monitor air quality using gas detection equipment.
- Never carry out hot work in explosive atmospheres or areas with active flammable gases or dust.
Real-Life Case or Scenario
On one site, sparks from grinding ignited sawdust and flammable materials that had built up on the floor. The fire spread rapidly, causing serious property damage and putting workers in danger. It was later determined that combustibles hadn’t been cleared and no fire watch had been assigned. The incident could have been avoided with better preparation and follow-up.
Employee Responsibilities
- Confirm all permits and inspections are completed before starting.
- Remove or shield combustible materials before starting work.
- Use fire extinguishing gear correctly and keep it nearby.
- Follow fire watch procedures, including monitoring after the work is completed.
- Report any unsafe conditions or faulty gear right away.
Employer Responsibilities
Discussion & Questions
Commitment/Action Plan
Let’s commit to checking the work area for combustibles, securing fire permits, and following every hot work safety step before starting any task. Each person on site plays a role in ensuring fire prevention.
Wrap-Up
Fire prevention during hot work is essential for protecting people, property, and productivity. By following these practices and complying with Canadian Centre for Occupational Health and Safety (CCOHS) regulations, we can reduce the risk of fire and make our worksites safer for everyone. Thanks for taking safety seriously.
Standards Overview
- Employers must manage risks from hot work, including fire and explosion hazards.
- A Hot Work Permit must be issued for any welding, grinding, or cutting done outside designated safe areas.
- Fire watches, ventilation, and fire safety equipment must be in place and used correctly.
- Pre-work inspections and training are essential to meeting legal duties and protecting workers.
Disclaimer
“The information provided in this toolbox talk is intended for informational and educational purposes only. It is not a substitute for professional legal, safety, or regulatory advice. The content reflects general best practices and industry standards but may not be applicable to all workplace environments or jurisdictions.
It is the responsibility of employers, supervisors, and workers to ensure compliance with applicable federal, provincial, and territorial laws, regulations, and standards, including but not limited to those set by the Canadian Centre for Occupational Health and Safety (CCOHS) and relevant provincial occupational health and safety authorities. Site App Pro, its affiliates, agents, or representatives—as well as the authors, presenters, and distributors of this toolbox talk—assume no liability for the use or application of the information provided.
Participants are strongly encouraged to consult appropriate legal, safety, or regulatory professionals regarding specific workplace concerns or questions. Always adhere to your organisation’s policies and procedures for health and safety and hazard management.
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