RAMS for Hot Works

Risk Assessment and Method Statement Template for Hot Works

This document should not be used until it has been thoroughly reviewed by a competent person.

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RAMS : Hot Works

Site Specific Instructions

Preparation and Planning

Ensure all personnel involved in hot works are adequately trained and competent.

Conduct a pre-work inspection of the area to identify potential fire hazards and ensure the availability of fire-fighting equipment.

Establish a designated hot works area, ensuring it is clear of flammable materials and has adequate ventilation.

Obtain necessary permits for hot works and ensure they are prominently displayed.

MIG Welding Process

Inspect welding equipment for defects or damage before use.

Ensure proper grounding of the welding machine to prevent electrical hazards.

Use appropriate personal protective equipment (PPE), including welding helmets, gloves, and flame-resistant clothing.

Maintain a safe distance from other workers and ensure the work area is free from obstructions.

TIG Welding Process

Verify the integrity of the TIG welding equipment, including the torch, cables, and gas supply.

Utilise suitable PPE, such as welding helmets with appropriate filter lenses, gloves, and protective clothing.

Ensure the workpiece is securely clamped to prevent movement during welding.

Monitor gas flow rates to prevent gas leaks and ensure a stable arc.

Use of Plasma Cutter

Inspect the plasma cutter for any signs of wear or damage prior to operation.

Confirm that all connections are secure and that the air supply is clean and dry.

Wear appropriate PPE, including eye protection with suitable filter lenses, gloves, and flame-resistant clothing.

Ensure the workpiece is properly supported and that sparks are directed away from flammable materials.

Post-Work Procedures

Conduct a thorough inspection of the work area to ensure no smouldering materials remain.

Allow sufficient cooling time for all equipment and materials before handling or storage.

Complete all necessary documentation, including permit closure and recording any incidents or near misses.

Associated Hazards:

Fire Risk: Sparks and molten metal can ignite flammable materials. Ensure fire extinguishers are readily available.

Electric Shock: Faulty equipment or improper grounding can lead to electric shock. Regularly inspect equipment and use proper grounding techniques.

Fumes and Gases: Welding and cutting processes can produce harmful fumes. Ensure adequate ventilation or use local exhaust systems.

Eye Injury: Intense light from welding arcs can cause eye damage. Use appropriate eye protection with correct filter lenses.

Burns: Hot metal and equipment can cause burns. Use suitable PPE to protect against heat exposure.

Site Specific Hazards

Fire : Low (1)

Who might be harmed: Operatives | Site workers | Visitors | Contractors

Type of harm: Burns | Death | Smoke Inhalation

Initial Risk: Catastrophic (5) x Probable (4) = High (20)
Controls

Ensure a fire watch is present during and after hot works to monitor for any signs of fire.

Remove or protect combustible materials within a 10-metre radius of the hot works area.

Use fire-retardant blankets or screens to contain sparks and heat.

Have appropriate fire extinguishers readily available and ensure personnel are trained in their use.

Conduct a hot works permit system to assess and control fire risks before commencing work.

Ensure adequate ventilation to prevent the accumulation of flammable gases.

Inspect and maintain equipment regularly to prevent malfunctions that could lead to fire.

Establish clear emergency procedures and ensure all personnel are familiar with them.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Explosion : Low (1)

Who might be harmed: Operatives | Site workers | Visitors | Contractors

Type of harm: Amputation | Broken Bones | Burns | Death | Eye Damage | Head Injury | Multiple / Various Injury | Permanent Hearing Damage | Smoke Inhalation

Initial Risk: Major (3) x Frequent (5) = Medium (15)
Controls

Ensure all flammable materials are removed from the vicinity of the hot works area.

Conduct a thorough inspection of gas cylinders and connections for leaks prior to use.

Utilise appropriate fire-retardant barriers or screens to contain sparks and heat.

Implement a hot work permit system to ensure all safety checks are completed before commencing work.

Provide adequate ventilation to disperse any flammable gases or vapours.

Ensure fire extinguishers are readily accessible and personnel are trained in their use.

Designate a fire watch to monitor the area during and after hot works activities.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Electric shock : Low (1)

Who might be harmed: Operatives | Site workers | Maintenance personnel

Type of harm: Burns | Death | Electrocution

Initial Risk: Catastrophic (5) x Frequent (5) = High (25)
Controls

Ensure all welding equipment is properly earthed and regularly inspected for damage.

Use insulated tools and wear appropriate personal protective equipment, including rubber-soled boots and insulated gloves.

Verify that all electrical connections are secure and free from moisture before commencing work.

Implement a lockout/tagout procedure to ensure equipment is de-energised during maintenance or repair.

Maintain a safe distance from live electrical components and avoid contact with conductive materials.

Provide training for workers on the risks of electric shock and the correct use of equipment.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Fumes and gases : Low (1)

Who might be harmed: Operatives | Site workers | Maintenance personnel

Type of harm: Asphyxia | Death | Illness | Respiratory damage / Asthma / COPD | Smoke Inhalation

Initial Risk: Severe (4) x Probable (4) = Medium (16)
Controls

Ensure adequate ventilation is provided in the work area to disperse fumes and gases effectively.

Use local exhaust ventilation systems to capture and remove fumes at the source.

Provide and enforce the use of appropriate respiratory protective equipment for workers.

Conduct air monitoring to assess the concentration of hazardous fumes and gases.

Implement a permit-to-work system to control and monitor hot works activities.

Train workers on the hazards of fumes and gases and the correct use of control measures.

Limit the duration of exposure by rotating workers or scheduling breaks.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Burns : Low (1)

Who might be harmed: Operatives | Site workers | Visitors | Contractors

Type of harm: Burns | Death | Eye Damage | Multiple / Various Injury

Initial Risk: Major (3) x Frequent (5) = Medium (15)
Controls

Ensure all personnel involved in hot works wear appropriate personal protective equipment, including flame-resistant clothing, gloves, and face shields.

Establish a designated hot works area with clear signage and barriers to prevent unauthorised access.

Conduct a thorough inspection of the work area to remove or protect any flammable materials before commencing hot works.

Utilise fire-resistant blankets or screens to shield nearby equipment and surfaces from sparks and heat.

Provide fire extinguishers and other firefighting equipment in close proximity to the hot works area.

Implement a hot works permit system to ensure all safety measures are in place and understood by all personnel.

Ensure adequate ventilation in the work area to dissipate heat and prevent the accumulation of flammable gases.

Assign a fire watch to monitor the work area during and after hot works to promptly address any signs of fire or excessive heat.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Eye damage : Low (1)

Who might be harmed: Operatives | Site workers | Visitors | Contractors | Nearby workers

Type of harm: Eye Damage

Initial Risk: Major (3) x Occasional (3) = Medium (9)
Controls

Ensure all personnel involved in hot works wear appropriate welding helmets with suitable filter lenses to protect against harmful radiation.

Provide safety goggles or face shields for additional protection against flying sparks and debris.

Implement a clear demarcation zone around the hot works area to prevent unauthorised personnel from entering without proper eye protection.

Regularly inspect and maintain eye protection equipment to ensure it is in good condition and provides adequate protection.

Conduct training sessions for workers on the importance of using eye protection and the risks associated with hot works.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Noise : Low (1)

Who might be harmed: Operatives | Site workers | Subcontractors

Type of harm: Permanent Hearing Damage

Initial Risk: Catastrophic (5) x Probable (4) = High (20)
Controls

Ensure all personnel in the vicinity of hot works wear appropriate hearing protection such as earplugs or earmuffs.

Conduct noise assessments to identify areas where noise levels exceed safe limits and implement necessary controls.

Limit the duration of exposure to high noise levels by rotating workers and scheduling breaks.

Utilise noise barriers or screens to reduce the transmission of noise to surrounding areas.

Maintain equipment regularly to ensure it operates efficiently and does not produce excessive noise.

Provide training to workers on the risks associated with noise and the importance of using hearing protection.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Hot surfaces : Low (1)

Who might be harmed: Operatives | Site workers | Maintenance personnel

Type of harm: Burns | Death | Multiple / Various Injury

Initial Risk: Major (3) x Frequent (5) = Medium (15)
Controls

Ensure all personnel wear appropriate heat-resistant personal protective equipment, including gloves and aprons.

Implement a designated cooling area for hot materials and tools to prevent accidental contact.

Use thermal barriers or shields to separate hot surfaces from work areas and pathways.

Clearly mark and signpost areas with hot surfaces to alert workers of potential hazards.

Provide training on the identification and handling of hot surfaces to all personnel involved in hot works.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Flying sparks : Low (1)

Who might be harmed: Operatives | Site workers | Nearby personnel

Type of harm: Burns | Eye Damage | Cuts and Abrasions

Initial Risk: Catastrophic (5) x Frequent (5) = High (25)
Controls

Ensure that all personnel wear appropriate personal protective equipment, including flame-resistant clothing, gloves, and eye protection.

Utilise welding screens or curtains to contain sparks within the designated work area.

Maintain a clear and tidy workspace, free from flammable materials and debris.

Position fire extinguishers and fire blankets in close proximity to the work area for immediate access.

Implement a fire watch procedure during and after hot works to monitor for any stray sparks or fires.

Ensure adequate ventilation to disperse any fumes or gases generated by the hot works.

Conduct a thorough inspection of the work area prior to commencing hot works to identify and mitigate potential hazards.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Confined space risks : Low (1)

Who might be harmed: Operatives | Site workers | Emergency responders

Type of harm: Asphyxia | Crush / Entrapment | Death | Drowning | Respiratory damage / Asthma / COPD | Smoke Inhalation

Initial Risk: Catastrophic (5) x Occasional (3) = Medium (15)
Controls

Ensure adequate ventilation is provided to prevent the accumulation of hazardous fumes and gases.

Conduct atmospheric testing to monitor oxygen levels and the presence of toxic gases before and during hot works.

Implement a permit-to-work system to ensure all safety procedures are followed and documented.

Provide appropriate personal protective equipment, including respiratory protection, to workers involved in hot works.

Establish an emergency rescue plan with trained personnel and necessary equipment readily available.

Limit the number of personnel within the confined space to essential workers only.

Ensure continuous communication is maintained between workers inside the confined space and those outside.

Residual Risk: Minor (1) x Improbable (1) = Low (1)
Procedures

Personnel and competence

All personnel involved in hot works, including MIG welding, TIG welding, and the use of a plasma cutter, must possess the requisite qualifications and experience. Competency certificates for each specific task must be verified prior to commencement.

Personnel must undergo a site-specific induction that includes detailed information on the risks associated with hot works and the control measures in place. This induction will cover the correct use of personal protective equipment (PPE), fire prevention strategies, and emergency procedures.

Only authorised personnel are permitted to perform hot works. A register of authorised personnel will be maintained and regularly updated. Supervisors must ensure that all operatives are aware of their responsibilities and are competent in the use of equipment and safety protocols.

Regular toolbox talks will be conducted to reinforce safe working practises and address any site-specific issues or changes in procedure. Attendance at these talks is mandatory for all personnel involved in hot works.

In the event of any changes to personnel, a competency assessment must be conducted to ensure that new operatives meet the required standards before they are allowed to engage in hot works activities.

Site inductions and training

All personnel involved in hot works, including MIG welding, TIG welding, and the use of a plasma cutter, must undergo a comprehensive site induction prior to commencing any activities. This induction will cover the specific risks associated with hot works and the control measures in place to mitigate these risks.

Key Points:

Mandatory Training: All operatives must have completed relevant training in hot works procedures, including fire safety awareness and the safe operation of welding and cutting equipment. Certification of training must be verified and documented.

Hot Works Permit: Personnel must be briefed on the requirement for a hot works permit, which must be obtained before any hot works commence. The permit process will be explained during the induction.

Fire Watch Duties: Individuals assigned as fire watchers must receive additional training on their responsibilities, including monitoring for potential fire hazards during and after hot works activities.

Emergency Procedures: The induction will include detailed instructions on emergency procedures specific to hot works, such as the location of fire extinguishers, fire blankets, and emergency exits.

PPE Requirements: Operatives will be instructed on the specific personal protective equipment (PPE) required for hot works, including flame-resistant clothing, welding helmets, gloves, and eye protection.

Equipment Handling: Training will cover the correct handling and maintenance of welding and cutting equipment to prevent accidents and ensure operational safety.

Attendance at the site induction is compulsory, and records of attendance will be maintained. Any personnel who have not completed the induction will not be permitted to engage in hot works activities.

Access and egress arrangements

All personnel involved in hot works, including MIG welding, TIG welding, and the use of a plasma cutter, must utilise designated access routes to and from the work area. These routes shall be clearly marked and free from obstructions to ensure safe passage.

Access Points:
Access points to the work area must be controlled and monitored to prevent unauthorised entry. Only trained and authorised personnel are permitted to enter the hot works zone.

Signage:
Appropriate signage indicating “Hot Works in Progress” must be prominently displayed at all entry points to alert individuals of potential hazards.

Fire Watch Personnel:
Fire watch personnel must have unobstructed access to all areas where hot works are being conducted. They should be positioned strategically to monitor for any signs of fire or smoke.

Emergency Egress:
Emergency egress routes must be identified and kept clear at all times. All personnel must be briefed on these routes during site inductions, ensuring they are aware of the quickest and safest exit in case of an emergency.

Lighting:
Adequate lighting must be provided along access and egress routes, especially in low-light conditions, to prevent trips and falls.

Ventilation:
Ensure that access routes do not compromise ventilation systems designed to disperse fumes and smoke generated by hot works. Proper ventilation must be maintained to protect the health of workers and maintain clear visibility.

Equipment Transport:
When transporting welding equipment or plasma cutters, ensure that cables and hoses do not obstruct access routes. Equipment should be moved with care to avoid creating tripping hazards.

Regular Inspections:
Conduct regular inspections of access and egress routes to ensure they remain safe and compliant with health and safety standards throughout the duration of the hot works activities.

Welfare

All personnel involved in hot works, including MIG and TIG welding and the use of a plasma cutter, shall have access to adequate welfare facilities. These facilities must be located at a safe distance from the hot works area to prevent exposure to fumes and heat.

Rest Areas: Designated rest areas must be provided, ensuring they are free from any risk of fire or exposure to hazardous substances. These areas should be equipped with appropriate seating and shelter from adverse weather conditions.

Hygiene Facilities: Adequate washing facilities must be available, including running water, soap, and towels. These facilities are essential for removing any contaminants that may be present on the skin following hot works activities.

Drinking Water: Potable drinking water must be readily accessible to all workers. It is crucial to ensure hydration, particularly when working in environments with elevated temperatures due to hot works.

First Aid: A fully stocked first aid kit must be available on-site, with personnel trained in first aid present during all hot works activities. This is vital for addressing any injuries promptly, such as burns or cuts.

Ventilation: Ensure that welfare areas are well-ventilated to prevent the accumulation of fumes and smoke from the hot works. This is critical for maintaining air quality and safeguarding the health of all personnel.

Fire Safety: Fire extinguishers and other fire-fighting equipment must be strategically placed near welfare facilities. All personnel should be trained in their use to respond effectively in the event of a fire.

By adhering to these specific procedures, the welfare of all personnel engaged in hot works will be adequately safeguarded, ensuring compliance with health and safety regulations.

Special permits

Prior to commencing any hot works, a Hot Work Permit must be obtained. This permit is essential to ensure that all necessary precautions are in place to mitigate fire risks associated with MIG welding, TIG welding, and the use of a plasma cutter.

The following procedures must be adhered to:

Permit Application: The responsible person must complete a Hot Work Permit application, detailing the specific tasks, location, and duration of the hot works. This application should be submitted to the site manager or designated safety officer for approval.

Risk Assessment Review: The permit issuer must review the risk assessment associated with the hot works to ensure all identified hazards have been addressed and appropriate control measures are in place.

Site Inspection: Prior to issuing the permit, a thorough inspection of the work area must be conducted. This includes checking for flammable materials, ensuring adequate ventilation, and verifying that fire-fighting equipment is readily accessible.

Permit Issuance: Once satisfied that all safety measures are in place, the permit issuer will authorise the Hot Work Permit. The permit must be prominently displayed at the work site throughout the duration of the hot works.

Monitoring and Supervision: A competent person must be assigned to monitor the hot works continuously. This individual is responsible for ensuring compliance with safety procedures and has the authority to halt work if conditions become unsafe.

Permit Duration and Expiry: The Hot Work Permit is valid only for the specified duration. Should the work extend beyond this period, a new permit must be obtained. Upon completion of the hot works, the permit must be signed off by the responsible person to confirm that the area has been inspected and deemed safe.

Post-Work Inspection: After completion of the hot works, a final inspection must be conducted to ensure no smouldering materials remain and that all equipment is safely stored.

Adherence to these procedures is crucial to maintaining a safe working environment during hot works activities.

Tools and equipment

All tools and equipment utilised for hot works, including MIG welding, TIG welding, and the use of a plasma cutter, must be inspected prior to use to ensure they are in good working condition. This includes checking for any visible damage or wear that could compromise safety.

Only trained and competent personnel are authorised to operate the equipment. Operators must be familiar with the manufacturer’s instructions and safety guidelines specific to each piece of equipment.

Fire extinguishers must be readily accessible at all times during hot works. The type and number of extinguishers should be appropriate for the materials being worked on and the potential fire risks associated with the specific hot work activities.

Ventilation systems must be in place to manage fumes and smoke generated by welding and cutting processes. This may include local exhaust ventilation or portable extraction units, depending on the site conditions and the nature of the work.

All electrical equipment must be PAT tested and certified safe for use. Cables and connections should be checked for integrity, ensuring there are no exposed wires or faulty connections.

Personal protective equipment (PPE), such as welding helmets, gloves, aprons, and flame-resistant clothing, must be worn at all times during hot works. PPE should be inspected regularly for damage and replaced as necessary.

A designated hot works area should be established, clearly marked, and free from combustible materials. Fire blankets or screens may be used to contain sparks and prevent them from reaching flammable substances.

Regular monitoring of equipment performance and environmental conditions is essential to ensure ongoing safety throughout the duration of the hot works. Any issues identified must be addressed immediately to prevent accidents or incidents.

Services and isolations

Prior to commencing any hot works, it is imperative to ensure that all relevant services are appropriately isolated to prevent any potential hazards. Electrical isolations must be conducted to ensure that no live wires are present in the vicinity of the welding and cutting activities. This involves liaising with a qualified electrician to confirm that all necessary circuits are de-energised and locked out.

Gas supplies in the area must be identified and isolated. This includes ensuring that any gas cylinders used for welding are stored securely and away from the work area when not in use. The isolation of gas services should be verified by a competent person, and all isolations must be documented.

Fire detection systems in the vicinity of the hot works must be temporarily disabled to prevent false alarms. This should be coordinated with the site manager and fire safety officer, ensuring that alternative fire watch measures are in place during this period.

All water services should be assessed to ensure they do not pose a risk of contact with electrical equipment or create slip hazards. If necessary, water supplies should be isolated or redirected.

Upon completion of the hot works, all services must be reinstated by competent personnel, ensuring that systems are fully operational and safe for use. Documentation of all isolations and reinstatements must be maintained as part of the project records.

Hazardous substances

All personnel involved in hot works, including MIG and TIG welding and the use of a plasma cutter, must adhere to strict procedures regarding hazardous substances.

Identification and Assessment:
Prior to commencing any hot works, a comprehensive assessment of all hazardous substances involved must be conducted. This includes identifying fumes and gases generated during welding and cutting processes, such as ozone, nitrogen oxides, and metal fumes.

Control Measures:

Ventilation: Ensure adequate ventilation is in place to disperse harmful fumes. Local exhaust ventilation (LEV) systems should be utilised where possible to capture fumes at the source.

Substitution: Where feasible, substitute hazardous materials with less harmful alternatives.

Isolation: Segregate hot works from other activities to prevent exposure to other workers.

Personal Protective Equipment (PPE):
All operatives must wear appropriate PPE, including respiratory protective equipment (RPE) suitable for the specific substances encountered. Ensure that RPE is fit-tested and maintained regularly.

Storage and Handling:
Hazardous substances must be stored in accordance with the Control of Substances Hazardous to Health (COSHH) regulations. Ensure that all containers are clearly labelled and that Material Safety Data Sheets (MSDS) are readily available on site.

Training and Competence:
Personnel must receive training on the safe handling and use of hazardous substances specific to hot works. This includes understanding the risks associated with exposure and the correct use of control measures.

Monitoring and Review:
Regular monitoring of air quality should be conducted to ensure that exposure levels remain within safe limits. Procedures should be reviewed periodically and updated as necessary to reflect any changes in work practises or substances used.

Deliveries and materials handling

All deliveries of materials and equipment related to hot works, including welding rods, gas cylinders, and plasma cutter consumables, shall be scheduled during designated delivery times to minimise disruption. The site manager must be notified in advance of any deliveries to ensure appropriate arrangements are in place.

Upon arrival, delivery vehicles must be directed to the designated unloading area by a competent person. It is imperative that all personnel involved in the unloading process wear appropriate personal protective equipment (PPE), including gloves and safety boots, to prevent injuries.

Gas cylinders must be handled with extreme care. They should be transported using appropriate trolleys or carriers designed for cylinder movement. Cylinders must be stored upright and secured in a well-ventilated area away from sources of ignition.

Welding rods and consumables should be stored in a dry, secure location to prevent contamination and deterioration. Only the required quantity for immediate use should be taken to the work area to minimise clutter and potential hazards.

All materials handling activities must be supervised by a competent person to ensure compliance with manual handling regulations. Mechanical aids should be utilised wherever possible to reduce the risk of injury.

In the event of any spillage or damage during delivery, the site manager must be informed immediately, and appropriate spill response procedures must be enacted to mitigate any risks associated with hazardous materials.

PPE

All personnel involved in hot works, including MIG welding, TIG welding, and the use of a plasma cutter, must adhere to the following Personal Protective Equipment (PPE) procedures:

Welding Helmets: All operatives must wear appropriate welding helmets with suitable filter lenses to protect against arc eye and harmful radiation. The helmet should be in good condition and fit securely.

Flame-Resistant Clothing: Workers are required to wear flame-resistant clothing that covers the full body. This includes long-sleeved shirts and trousers made from materials that resist ignition and do not melt.

Welding Gloves: Heavy-duty welding gloves must be worn to protect hands from heat, sparks, and potential burns. These gloves should be insulated and provide adequate dexterity for handling equipment.

Safety Boots: Steel-toed safety boots with heat-resistant soles are mandatory to protect feet from falling objects and hot materials.

Respiratory Protection: Where ventilation is insufficient, appropriate respiratory protection must be used to prevent inhalation of fumes and gases. The type of respirator will depend on the specific materials being welded or cut.

Hearing Protection: Ear protection, such as earplugs or earmuffs, should be worn to safeguard against noise levels that exceed safe thresholds during hot works operations.

Eye Protection: In addition to welding helmets, safety goggles or glasses with side shields should be worn when there is a risk of flying particles or when performing tasks adjacent to welding activities.

Face Shields: When using a plasma cutter, operatives must wear face shields in conjunction with safety goggles to protect against sparks and debris.

High-Visibility Vests: If working in areas where visibility is crucial, high-visibility vests should be worn over flame-resistant clothing to ensure operatives are easily seen by others on site.

All PPE must be inspected prior to use to ensure it is in good condition and fit for purpose. Any damaged or defective equipment must be replaced immediately. Compliance with these procedures is mandatory to ensure the safety and well-being of all personnel involved in hot works activities.

Emergency procedures

In the event of an emergency during hot works, the following procedures must be adhered to:

Immediate Cessation of Work: All hot works, including MIG welding, TIG welding, and the use of a plasma cutter, must be stopped immediately upon identification of an emergency situation.

Alerting Personnel: The individual who identifies the emergency must promptly alert all personnel in the vicinity by shouting “Fire” or “Emergency” and activating the nearest fire alarm.

Evacuation: All personnel must evacuate the area using the designated escape routes. It is imperative to avoid using lifts and to proceed to the assembly point in an orderly manner.

Fire Extinguishing Measures: If safe to do so, trained personnel may attempt to extinguish small fires using appropriate fire extinguishers. It is crucial to ensure that the correct type of extinguisher is used for the specific fire hazard.

Isolation of Equipment: All welding and cutting equipment must be switched off and isolated from power sources to prevent further hazards.

Accountability: Upon reaching the assembly point, all personnel must report to the appointed fire marshal or site supervisor for a roll call to ensure everyone is accounted for.

Communication with Emergency Services: The site manager or designated safety officer must contact emergency services, providing them with detailed information about the nature of the emergency and any potential hazards related to hot works.

Post-Incident Review: After the emergency has been resolved, a thorough review must be conducted to assess the cause and effectiveness of the response. This review should inform any necessary amendments to procedures or training.

All personnel involved in hot works must be familiar with these procedures and participate in regular emergency drills to ensure preparedness.

Safety of public and occupiers

The safety of the public and occupiers during hot works is of paramount importance. Access to the work area must be strictly controlled to prevent unauthorised entry. This will be achieved by erecting physical barriers and clear signage indicating the presence of hot works and potential hazards.

Fire watch personnel will be stationed at strategic points to monitor for any signs of fire or smoke, both during and after the completion of hot works. They will be equipped with appropriate fire extinguishers and trained in their use.

A designated hot works zone will be established, ensuring that all flammable materials are removed or adequately shielded. The area will be inspected prior to commencement to confirm compliance with safety protocols.

Ventilation systems will be assessed to ensure that fumes and smoke do not migrate to occupied areas. If necessary, temporary ventilation solutions will be implemented to maintain air quality.

In the event of an emergency, clear evacuation routes will be maintained, and all personnel will be briefed on emergency procedures. Regular communication with occupiers will be maintained to keep them informed of the schedule and nature of the works.

Finally, a permit-to-work system will be enforced, ensuring that all hot works are authorised and conducted under controlled conditions. This system will include a thorough risk assessment and method statement review prior to approval.

Asbestos

All personnel involved in hot works must be vigilant for any materials suspected to contain asbestos. Prior to commencing any hot works, a thorough review of the asbestos survey report must be conducted to confirm the absence of asbestos-containing materials (ACMs) in the work area. No hot works shall commence until this confirmation is obtained.
In the event that ACMs are identified or suspected in the vicinity of the hot works, all activities must cease immediately. The area must be cordoned off, and a competent asbestos contractor should be engaged to assess and, if necessary, safely remove or encapsulate the ACMs. Under no circumstances should hot works be performed on or near ACMs.
All operatives must be briefed on the potential presence of asbestos and the procedures to follow if ACMs are encountered. This briefing should include recognising ACMs, understanding the risks associated with disturbing them, and knowing the emergency procedures to follow.

Regular monitoring of the work area should be conducted to ensure no inadvertent exposure to asbestos occurs during hot works. Any changes in site conditions that may affect the presence of ACMs must be reported immediately to the site supervisor.

Documentation of all checks, findings, and actions taken regarding asbestos must be maintained and readily available for inspection.

Monitoring

The monitoring of hot works activities, including MIG welding, TIG welding, and the use of a plasma cutter, shall be conducted with utmost diligence to ensure compliance with health and safety standards.

Continuous Monitoring: A designated competent person shall be present at all times during hot works operations to oversee activities and ensure adherence to safety protocols. This individual shall be responsible for identifying any deviations from the method statement and implementing corrective actions immediately.

Fire Watch: A fire watch shall be maintained during and for a minimum of 60 minutes after the completion of hot works. The fire watch personnel must be equipped with appropriate firefighting equipment and trained in its use. They shall remain vigilant for any signs of ignition or smouldering materials.

Atmospheric Monitoring: Regular checks shall be conducted to monitor the levels of fumes and gases produced during welding and cutting operations. This includes ensuring that adequate ventilation is maintained to prevent the accumulation of hazardous substances. Monitoring equipment shall be calibrated and maintained as per manufacturer’s instructions.

Temperature Checks: Surface temperatures in the vicinity of hot works shall be monitored to prevent overheating and potential ignition of nearby materials. Non-contact infrared thermometers may be utilised for this purpose.

Record Keeping: All monitoring activities, including observations and any incidents, shall be documented in a logbook. This documentation shall be reviewed regularly by the site supervisor to ensure ongoing compliance and to identify any trends that may require additional control measures.

Communication: Any issues identified during monitoring must be communicated immediately to the site manager and relevant personnel. A clear line of communication must be established to facilitate prompt response to any safety concerns.

By adhering to these specific procedures, the risks associated with hot works can be effectively managed, ensuring a safe working environment for all personnel involved.

Waste management

All waste materials generated from hot works, including MIG and TIG welding and the use of a plasma cutter, must be managed in accordance with the following procedures:

Segregation of Waste: All waste must be segregated at the source. Metal offcuts, slag, and other by-products from welding and cutting activities should be collected separately from general waste. Designated containers for metal waste must be clearly labelled and located in close proximity to the work area.

Collection and Storage: Waste containers must be fire-resistant and equipped with lids to prevent the escape of sparks or hot debris. These containers should be inspected regularly to ensure they are not overfilled and are in good condition.

Disposal of Hazardous Waste: Any hazardous waste, such as used welding rods or contaminated materials, must be disposed of in accordance with the Control of Substances Hazardous to Health (COSHH) regulations. A licenced waste carrier should be engaged for the removal of such materials.

Documentation: A waste transfer note must be completed for each consignment of waste removed from the site. This documentation should include details of the type and quantity of waste, as well as the destination for disposal or recycling.

Minimisation of Waste: Efforts should be made to minimise waste generation by optimising material usage and reusing offcuts where possible. Regular reviews of waste management practises should be conducted to identify opportunities for improvement.

Training and Awareness: All personnel involved in hot works must receive training on the specific waste management procedures relevant to their tasks. This includes understanding the importance of proper segregation, storage, and disposal of waste materials.

Emergency Procedures: In the event of a fire or spillage involving waste materials, emergency procedures must be followed immediately. Fire extinguishers and spill kits should be readily accessible, and personnel must be familiar with their use.

By adhering to these procedures, the project will ensure compliance with relevant legislation and contribute to a safer working environment.

Environmental considerations

All personnel involved in hot works, including MIG and TIG welding and the use of a plasma cutter, must adhere to the following environmental procedures to mitigate potential impacts:

Control of Emissions: Ensure that all welding and cutting activities are conducted in well-ventilated areas to minimise the concentration of fumes and gases. Where possible, use local exhaust ventilation systems to capture emissions at the source.

Waste Management: Collect and dispose of all metal offcuts, slag, and other waste materials in designated containers. Ensure that these materials are recycled or disposed of in accordance with local environmental regulations.

Noise Control: Implement noise reduction measures such as using sound barriers or enclosures around the work area to minimise disturbance to nearby residents and wildlife. Schedule noisy activities during designated hours to reduce impact.

Spill Prevention: Store all hazardous substances, including welding gases and coolants, in secure, bunded areas to prevent accidental spills. In the event of a spill, follow the spill response procedure immediately to contain and clean up the substance.

Energy Efficiency: Utilise energy-efficient equipment where possible and ensure that all machinery is switched off when not in use to conserve energy.

Fire Prevention: Maintain a clear area around the hot works site free from flammable materials. Use fire-retardant blankets or screens to contain sparks and prevent them from igniting surrounding materials.

Water Pollution Prevention: Ensure that no contaminants from hot works enter nearby watercourses. Use drip trays under equipment to catch any leaks or drips, and dispose of collected fluids appropriately.

By adhering to these procedures, the project will minimise its environmental footprint while conducting hot works safely and efficiently.

Near neighbours and nuisance

The project team shall ensure that all hot works, including MIG welding, TIG welding, and the use of a plasma cutter, are conducted in a manner that minimises disruption to near neighbours. Noise levels shall be monitored and controlled by using equipment with noise-dampening features where possible. Operations shall be scheduled during standard working hours to avoid disturbance during early mornings, evenings, and weekends.

Communication with neighbours is paramount. Prior to commencing hot works, the project manager shall inform nearby residents and businesses of the schedule and nature of the activities. Contact details for a designated liaison officer shall be provided to address any concerns promptly.

To mitigate fumes and odours, appropriate ventilation systems shall be employed. Where feasible, temporary barriers or screens shall be erected to contain fumes within the work area. Regular checks shall be conducted to ensure that these measures are effective.

Visual impact shall be minimised by maintaining a tidy worksite and ensuring that all equipment and materials are stored neatly when not in use. Lighting used during hot works shall be directed away from neighbouring properties to prevent light pollution.

In the event of any complaints or issues arising from the hot works, the project team shall respond swiftly to investigate and resolve the matter, ensuring that all actions taken are documented for future reference.

Occupational health

All personnel involved in hot works, including MIG and TIG welding and the use of a plasma cutter, must undergo a pre-task health assessment to ensure they are fit for the task. Regular monitoring of workers’ health is essential to identify any adverse effects from exposure to fumes and heat.

Ventilation is critical to minimise inhalation of hazardous fumes. Ensure that all work areas are equipped with adequate local exhaust ventilation systems. Where natural ventilation is insufficient, mechanical ventilation must be employed.

Personal Protective Equipment (PPE) is mandatory. Workers must wear appropriate respiratory protection, such as fume extraction masks, to prevent inhalation of harmful substances. Additionally, flame-resistant clothing, gloves, and eye protection must be worn at all times.

Heat stress management procedures must be implemented. This includes providing regular breaks in a cool area, ensuring access to drinking water, and monitoring workers for signs of heat-related illnesses.

Noise exposure should be assessed and controlled. Ear protection must be provided and worn when noise levels exceed the recommended exposure limits.

Training on the safe handling of equipment and materials is essential. Workers must be informed about the potential health risks associated with hot works and the measures in place to mitigate these risks.

In case of any health concerns or incidents, immediate reporting to the site supervisor is required, followed by an appropriate response as per the emergency procedures outlined in the project plan.

Amendments and authorisation

All amendments to the method statement for hot works, including MIG welding, TIG welding, and the use of a plasma cutter, must be formally documented and authorised prior to implementation.

Initiation of Amendments: Any proposed changes to the procedures must be initiated by the site supervisor or a competent person directly involved in the hot works activities. The rationale for the amendment should be clearly stated, with reference to specific safety concerns or operational requirements.

Review Process: The proposed amendment must be reviewed by the Health and Safety Advisor to ensure compliance with relevant legislation and safety standards. This review should consider the potential impact on fire safety, ventilation requirements, and the adequacy of existing control measures.

Authorisation: Once reviewed, the amendment must be authorised by the Project Manager. Authorisation is contingent upon confirmation that all necessary risk assessments have been updated to reflect the changes and that all personnel involved in hot works are informed of the new procedures.

Communication: The authorised amendment must be communicated to all relevant personnel, including welders, cutters, and fire watch personnel. This communication should be documented, and a briefing session should be conducted to ensure understanding of the new procedures.

Documentation: All amendments must be recorded in the project documentation, with a clear audit trail indicating the date of amendment, details of the change, and signatures of those who reviewed and authorised the amendment.

Monitoring: Following implementation, the effectiveness of the amended procedures should be monitored regularly to ensure they adequately address the identified risks and do not introduce new hazards.

By adhering to these procedures, the project ensures that any changes to hot works activities are managed safely and effectively, maintaining compliance with health and safety regulations.

Activities

Preparation and Setup

Conduct a thorough risk assessment of the work area to identify potential hazards associated with hot works.

Ensure all operatives have received appropriate training and are competent in the tasks they are to perform.

Verify that all necessary permits for hot works have been obtained and are valid for the duration of the task.

Inspect all equipment, including welding machines and plasma cutters, to ensure they are in good working condition and have been maintained according to manufacturer guidelines.

Clear the work area of any flammable materials or substances, maintaining a safe distance from the hot works zone.

Set up fire-resistant barriers or screens to protect surrounding areas and personnel from sparks and heat.

Ensure adequate ventilation is available to disperse fumes and smoke generated during hot works.

Position fire extinguishers and other firefighting equipment within easy reach of the work area.

Establish a fire watch with trained personnel to monitor for any signs of fire during and after the hot works.

Ensure all operatives are equipped with appropriate personal protective equipment (PPE), including welding helmets, gloves, aprons, and safety boots.

Confirm that all electrical connections are secure and that cables are routed safely to prevent tripping hazards.

Conduct a pre-work briefing with all operatives to review the method statement, emergency procedures, and roles and responsibilities.

Mark out a designated safe zone for operatives not directly involved in the hot works to observe from a safe distance.

Test all equipment in a controlled manner to ensure functionality before commencing the main tasks.

Equipment Inspection and Maintenance

Ensure all equipment is powered off and disconnected from any power sources before commencing inspection.

Visually inspect all welding and cutting equipment for signs of damage, wear, or corrosion, paying particular attention to cables, hoses, and connections.

Check the integrity of all safety guards and covers, ensuring they are securely in place and undamaged.

Verify that all gas cylinders are properly secured and that regulators and valves are functioning correctly without leaks.

Inspect the condition of welding torches and plasma cutters, ensuring nozzles and tips are clean and free from obstructions.

Examine all electrical components for signs of overheating or damage, including plugs, sockets, and switches.

Test all safety features, such as emergency stop buttons and thermal overload protection, to ensure they are operational.

Clean equipment surfaces to remove any dust, debris, or residue that may affect performance or safety.

Lubricate moving parts as per the manufacturer’s recommendations to ensure smooth operation.

Record all findings in the equipment maintenance log, noting any defects or issues that require repair or replacement.

Report any significant defects immediately to the site supervisor and arrange for necessary repairs before equipment is used.

Reconnect equipment to power sources only after confirming that all inspections and maintenance tasks have been satisfactorily completed.

Personal Protective Equipment (PPE) Allocation

Conduct a pre-task briefing to ensure all operatives understand the specific PPE requirements for each hot work task.

Inspect all PPE for damage or defects prior to use, ensuring it meets the relevant safety standards.

Don appropriate flame-resistant clothing that covers all exposed skin, including long sleeves and trousers.

Wear a welding helmet with the correct shade filter for MIG and TIG welding to protect eyes and face from arc flash.

Use safety goggles or a face shield when operating a plasma cutter to guard against flying debris and intense light.

Equip heat-resistant gloves to protect hands from burns and hot surfaces.

Ensure steel-toed boots with non-slip soles are worn to protect feet from heavy objects and hot materials.

Fit ear protection, such as earplugs or earmuffs, to safeguard against noise exposure from equipment operation.

Don a respirator or mask if working in an area with inadequate ventilation to prevent inhalation of fumes and particulates.

Secure all loose clothing, hair, and accessories to prevent entanglement or ignition.

Regularly check and adjust PPE during the task to maintain proper fit and protection.

After completing the task, carefully remove PPE, inspecting for any damage incurred during use, and store appropriately for future use.

MIG Welding Operations

Conduct a pre-work risk assessment to identify potential hazards and ensure all control measures are in place.

Ensure all operatives are wearing appropriate personal protective equipment (PPE), including welding helmets, gloves, flame-resistant clothing, and safety boots.

Inspect the MIG welding equipment for any damage or defects before use, ensuring all connections are secure and the equipment is in good working order.

Set up a designated welding area, ensuring it is well-ventilated and free from flammable materials or obstructions.

Position fire extinguishers and fire blankets within easy reach of the work area.

Connect the welding machine to a suitable power source, ensuring the correct voltage and amperage settings for the material being welded.

Securely clamp the workpiece to prevent movement during welding, using appropriate jigs or fixtures if necessary.

Attach the ground clamp to a clean, unpainted section of the workpiece to ensure a good electrical connection.

Insert the appropriate welding wire into the machine, ensuring it is compatible with the material being welded.

Adjust the wire feed speed and voltage settings on the machine according to the manufacturer’s guidelines and material specifications.

Perform a test weld on a scrap piece of material to verify settings and adjust as necessary for optimal weld quality.

Begin welding by holding the torch at the correct angle and maintaining a consistent travel speed to produce a uniform weld bead.

Continuously monitor the weld pool and adjust technique as necessary to prevent defects such as porosity or undercutting.

Periodically inspect the weld for quality and make any necessary adjustments to settings or technique.

Upon completion of welding, allow the workpiece to cool naturally before handling or moving it.

Inspect the finished weld for defects and ensure it meets the required specifications and standards.

Turn off and disconnect the welding machine from the power source once all welding operations are complete.

Clean up the work area, disposing of any waste materials in accordance with site procedures and environmental regulations.

Store all equipment and PPE in designated areas, ensuring it is ready for future use.

TIG Welding Operations

Conduct a pre-work risk assessment to identify potential hazards and ensure all control measures are in place.

Ensure all operatives are wearing appropriate personal protective equipment (PPE), including welding helmets with suitable filters, flame-resistant clothing, gloves, and safety boots.

Verify that the work area is well-ventilated to prevent the accumulation of harmful fumes and gases.

Inspect the TIG welding equipment, including the torch, cables, and gas supply, to ensure they are in good working condition and free from defects.

Set up a fire watch with appropriate fire extinguishing equipment readily available in case of an emergency.

Clear the work area of any flammable materials or substances to prevent fire hazards.

Secure the workpiece firmly in place using clamps or fixtures to prevent movement during welding.

Connect the TIG torch to the power source and adjust the settings according to the material type and thickness being welded.

Ensure the correct shielding gas is connected and flowing at the appropriate rate to protect the weld pool from contamination.

Strike an arc by bringing the tungsten electrode close to the workpiece without touching it, then initiate the welding process.

Maintain a consistent travel speed and torch angle to ensure a uniform weld bead.

Monitor the weld pool closely and adjust parameters as necessary to maintain quality and prevent defects.

Upon completion of welding, allow the workpiece to cool naturally before handling or moving it.

Inspect the weld for any defects or irregularities and perform any necessary repairs or touch-ups.

Clean the work area, ensuring all equipment is turned off and stored properly, and dispose of any waste materials in accordance with site procedures.

Complete any required documentation, including recording details of the work performed and any incidents or near misses.

Plasma Cutting Procedures

Conduct a pre-work risk assessment to identify potential hazards and ensure all control measures are in place.

Ensure all operatives are wearing appropriate personal protective equipment (PPE), including flame-resistant clothing, gloves, safety goggles, and a welding helmet with the appropriate shade.

Inspect the plasma cutter for any damage or defects, ensuring all connections are secure and the equipment is in good working order.

Set up a designated hot works area, ensuring it is clear of flammable materials and that fire extinguishers are readily accessible.

Establish adequate ventilation in the work area to prevent the accumulation of fumes and gases.

Connect the plasma cutter to the power supply and air compressor, ensuring all connections are secure and free from leaks.

Adjust the plasma cutter settings according to the material type and thickness to be cut, following the manufacturer’s guidelines.

Secure the workpiece on a stable surface, ensuring it is properly grounded to prevent electrical hazards.

Position the plasma cutter torch at the starting point of the cut, maintaining a safe distance from the workpiece.

Activate the plasma cutter and begin cutting, maintaining a steady hand and consistent speed to ensure a clean cut.

Continuously monitor the work area for any signs of fire or other hazards, ready to cease operations if necessary.

Upon completion of cutting, turn off the plasma cutter and disconnect it from the power supply and air compressor.

Allow the workpiece and surrounding area to cool before handling or moving any materials.

Inspect the cut for quality and accuracy, making any necessary adjustments or additional cuts as required.

Clean up the work area, disposing of any waste materials in accordance with site procedures and environmental regulations.

Conduct a post-work inspection to ensure all equipment is properly stored and the area is left in a safe condition.

Fire Safety and Prevention Measures

Conduct a thorough risk assessment to identify potential fire hazards in the work area prior to commencing hot works.

Ensure all operatives are trained in fire safety procedures and the use of fire extinguishing equipment.

Clear the work area of any flammable materials or substances, maintaining a minimum distance of 11 metres from the hot works site.

Use fire-retardant blankets or screens to shield any immovable flammable materials within the vicinity.

Ensure that appropriate fire extinguishers, such as CO2 or dry powder, are readily accessible and fully charged.

Assign a designated fire watch operative to monitor the work area during and for at least 30 minutes after completion of hot works.

Verify that all equipment, including welding torches and plasma cutters, is in good working condition and free from defects.

Ensure adequate ventilation is provided to prevent the accumulation of flammable gases or vapours.

Implement a permit-to-work system for all hot works, ensuring permits are authorised by a competent person before commencement.

Regularly inspect and maintain all personal protective equipment (PPE) to ensure it is fit for purpose.

Cease all hot works immediately if a fire hazard is identified, and take corrective action before resuming.

Upon completion of hot works, conduct a final inspection of the area to ensure no smouldering materials remain and all equipment is safely shut down.

Ventilation and Fume Extraction Management

Assess the work area to identify potential sources of fumes and ensure that adequate ventilation is available.

Position portable fume extractors or local exhaust ventilation systems as close to the source of fumes as possible, ensuring they do not obstruct the work area.

Verify that all ventilation and extraction equipment is in good working order, conducting pre-use checks for any signs of damage or malfunction.

Ensure that all operatives are trained in the use of ventilation and fume extraction equipment, including emergency procedures.

Activate the ventilation and fume extraction systems prior to commencing hot works to establish a safe working environment.

Monitor the effectiveness of the ventilation and extraction throughout the task, adjusting equipment as necessary to maintain optimal fume removal.

Regularly inspect filters and ducts for blockages or build-up of materials, cleaning or replacing them as required to maintain efficiency.

Ensure that all operatives wear appropriate personal protective equipment (PPE), such as respirators, if required by the risk assessment.

Upon completion of hot works, continue operating the ventilation and extraction systems for a sufficient period to clear residual fumes from the work area.

Conduct a final inspection of the work area to confirm that it is free from hazardous fumes before dismantling any temporary ventilation equipment.

Monitoring and Supervision

Assign a competent person to act as the Fire Watcher, responsible for monitoring the hot works area during and after the task.

Ensure the Fire Watcher is equipped with appropriate fire-fighting equipment, such as fire extinguishers, and is trained in their use.

Conduct a pre-work briefing with all operatives involved, highlighting specific risks and control measures associated with the hot works.

Establish a clear communication protocol between operatives and the Fire Watcher to report any incidents or concerns immediately.

Maintain a safe distance from the hot works area, ensuring that only authorised personnel are present.

Continuously monitor the work area for signs of fire, smoke, or any other hazards that may arise during the hot works.

Ensure that all safety barriers and warning signs are in place and remain intact throughout the duration of the task.

Regularly inspect the surrounding area for combustible materials and ensure they are removed or adequately protected.

After completion of the hot works, conduct a thorough inspection of the area to identify any smouldering materials or potential fire risks.

Maintain supervision for a minimum of 30 minutes post-completion to ensure no residual hazards remain.

Document any incidents or near misses in accordance with company procedures and report them to the site supervisor.

Emergency Procedures and First Aid

Ensure all operatives are familiar with the location of emergency exits and assembly points prior to commencing hot works.

Confirm that fire extinguishers, appropriate for the type of fire risk, are readily accessible and in good working order.

Designate a fire watch operative to monitor the work area during and after hot works, ensuring they are trained in emergency response procedures.

In the event of a fire, immediately cease all hot works and activate the nearest fire alarm.

If safe to do so, use a fire extinguisher to tackle small fires, ensuring the operative maintains a clear escape route at all times.

Evacuate the area promptly and proceed to the designated assembly point, ensuring all personnel are accounted for.

Contact emergency services by dialling 999, providing clear details of the incident and location.

Ensure first aid kits are fully stocked and accessible, with a trained first aider present on site at all times.

In case of injury, administer first aid as necessary, ensuring the injured person is moved to a safe area if required.

Record all incidents in the site accident book and report to the site manager for further investigation and action.

Cleaning Up and Waste Disposal

Allow all equipment and materials to cool down completely before handling.

Inspect the work area for any remaining sparks, embers, or hot materials, and extinguish them using appropriate fire extinguishing equipment.

Collect and segregate all waste materials, including metal offcuts, slag, and used consumables, ensuring they are placed in designated waste containers.

Dispose of hazardous waste, such as used welding rods and plasma cutter consumables, in accordance with local regulations and company procedures.

Clean the work area thoroughly, removing any debris, dust, or residue from surfaces using appropriate cleaning tools and methods.

Store all tools and equipment in their designated storage areas, ensuring they are in good condition and ready for future use.

Conduct a final inspection of the work area to ensure it is free from hazards and that all waste has been appropriately disposed of.

Complete any required documentation or checklists related to the cleaning and waste disposal process.

Report any issues or incidents encountered during the cleaning process to the site supervisor or health and safety officer.

Final Inspection and Sign-off

Allow sufficient cooling time for all materials and equipment used during hot works to ensure they are safe to handle.

Conduct a thorough visual inspection of the work area to identify any signs of residual heat, sparks, or smouldering materials.

Use appropriate detection equipment, such as thermal imaging cameras or heat detectors, to confirm the absence of residual heat in the work area.

Check all fire safety equipment, including fire extinguishers and fire blankets, to ensure they remain in their designated locations and are fully operational.

Verify that all flammable materials have been removed from the vicinity of the hot works area and stored safely.

Ensure that all tools and equipment used during the hot works are properly cleaned, maintained, and stored in their designated locations.

Confirm that all personal protective equipment (PPE) has been removed, inspected for damage, and stored appropriately.

Complete any required documentation, including hot works permits and inspection checklists, ensuring all relevant details are accurately recorded.

Obtain sign-off from the responsible supervisor or manager, confirming that the work area is safe and all procedures have been followed correctly.

Communicate with all relevant personnel to inform them that the hot works have been completed and the area is safe for normal operations to resume.

Hazardous Substances

Welding Fumes

Welding fumes are not intended for use; they are a by-product of welding processes and pose health risks, necessitating control measures to minimise exposure.

Inhalation : Low (1)

Who might be harmed: Welders | Nearby Workers

Type of harm: Asphyxia | Death | Illness | Respiratory damage / Asthma / COPD | Smoke Inhalation

Initial Risk: Severe (4) x Occasional (3) = Medium (12)
Controls

Ensure adequate ventilation in the work area to disperse fumes.

Use local exhaust ventilation systems to capture fumes at the source.

Provide and enforce the use of appropriate respiratory protective equipment.

Implement a fume extraction system specifically designed for welding activities.

Conduct regular air monitoring to assess fume levels and effectiveness of controls.

Limit the duration of exposure by rotating tasks among workers.

Train workers on the hazards of welding fumes and proper use of controls.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Eye Contact : Low (1)

Who might be harmed: Welders | Nearby Workers

Type of harm: Eye Damage

Initial Risk: Catastrophic (5) x Probable (4) = High (20)
Controls

Ensure all workers wear appropriate welding helmets with suitable filter lenses to protect against ultraviolet and infrared radiation.

Provide safety goggles or face shields for additional protection against flying particles and sparks.

Implement welding screens or curtains to shield nearby workers from exposure to welding arcs.

Conduct regular inspections and maintenance of personal protective equipment to ensure effectiveness.

Residual Risk: Minor (1) x Improbable (1) = Low (1)
Ozone

Ozone is not intentionally used in hot works; rather, it is a by-product generated during welding processes, particularly when ultraviolet light interacts with oxygen in the air.

Inhalation : Low (1)

Who might be harmed: Welders | Plasma Cutter Operators | Nearby Workers

Type of harm: Asphyxia | Death | Respiratory damage / Asthma / COPD | Smoke Inhalation

Initial Risk: Catastrophic (5) x Occasional (3) = Medium (15)
Controls

Ensure adequate ventilation in the work area to disperse ozone.

Use local exhaust ventilation systems to capture ozone at the source.

Implement administrative controls such as limiting exposure time to ozone.

Provide and enforce the use of appropriate respiratory protective equipment.

Conduct regular air monitoring to assess ozone concentration levels.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Eye Contact : Low (1)

Who might be harmed: Welders | Plasma Cutter Operators

Type of harm: Eye Damage

Initial Risk: Catastrophic (5) x Frequent (5) = High (25)
Controls

Wear safety goggles or face shields specifically designed to protect against ozone exposure.

Ensure proper ventilation in the work area to reduce ozone concentration.

Implement administrative controls to limit exposure time to ozone.

Residual Risk: Minor (1) x Improbable (1) = Low (1)
Nitrogen Oxides

Nitrogen Oxides are not intentionally used in hot works; rather, they are by-products generated during the welding process due to the high temperatures involved.

Inhalation : Low (1)

Who might be harmed: Welders | Plasma Cutter Operators | Nearby Workers

Type of harm: Asphyxia | Death | Respiratory damage / Asthma / COPD | Smoke Inhalation

Initial Risk: Severe (4) x Probable (4) = Medium (16)
Controls

Ensure adequate ventilation in the work area to disperse nitrogen oxides.

Use local exhaust ventilation systems to capture fumes at the source.

Provide workers with appropriate respiratory protective equipment, such as respirators with suitable filters.

Implement a monitoring system to regularly assess nitrogen oxide levels in the air.

Limit the duration of exposure by rotating tasks among workers.

Conduct regular training sessions on the hazards of nitrogen oxides and safe work practises.

Residual Risk: Minor (1) x Improbable (1) = Low (1)
Metal Fume (e.g., Chromium, Nickel)

Metal fume, such as chromium and nickel, is generated during welding or cutting processes involving metals and poses a significant inhalation risk to workers.

Inhalation : Low (1)

Who might be harmed: Welders | Plasma Cutter Operators | Nearby Workers

Type of harm: Asbestosis / Lung Cancer / Mesothelioma | Asphyxia | Death | Respiratory damage / Asthma / COPD | Smoke Inhalation

Initial Risk: Major (3) x Probable (4) = Medium (12)
Controls

Ensure local exhaust ventilation (LEV) systems are in place to capture fumes at the source.

Provide appropriate respiratory protective equipment (RPE) with suitable filters for metal fumes.

Conduct regular air monitoring to assess fume levels and ensure compliance with exposure limits.

Implement a fume extraction system to maintain adequate airflow and reduce fume concentration.

Train workers on the correct use and maintenance of RPE and LEV systems.

Residual Risk: Minor (1) x Improbable (1) = Low (1)
Argon

Argon is utilised as an inert shielding gas in TIG welding to protect the weld area from atmospheric gases, ensuring a clean and high-quality weld.

Inhalation : Low (1)

Who might be harmed: Welders | Plasma Cutter Operators | Nearby Workers

Type of harm: Asphyxia | Death | Respiratory damage / Asthma / COPD

Initial Risk: Catastrophic (5) x Occasional (3) = Medium (15)
Controls

Ensure adequate ventilation in the work area to prevent Argon accumulation.

Use local exhaust ventilation systems to capture and remove Argon at the source.

Implement oxygen monitoring systems to alert workers of low oxygen levels.

Provide workers with appropriate respiratory protective equipment if ventilation is insufficient.

Conduct regular air quality assessments to ensure safe Argon levels are maintained.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Induction Record

Company name: Project title:

Location: Contract No:

Subject: Method Statement : Hot Works Tutor:

Date: Signature:

This document has been provided as a template. By completing the section above, you take full responsibility for the use of this document.

Name Comments Signature Date

RAMS for Hot Works

Risk Assessment and Method Statement Template for Hot Works

RAMS : Hot Works

Site Specific Instructions

Site Specific Hazards

Procedures

Personnel and competence

Site inductions and training

Access and egress arrangements

Welfare

Special permits

Tools and equipment

Services and isolations

Hazardous substances

Deliveries and materials handling

PPE

Emergency procedures

Safety of public and occupiers

Asbestos

Monitoring

Waste management

Environmental considerations

Near neighbours and nuisance

Occupational health

Amendments and authorisation

Activities

Preparation and Setup

Equipment Inspection and Maintenance

Personal Protective Equipment (PPE) Allocation

MIG Welding Operations

TIG Welding Operations

Plasma Cutting Procedures

Fire Safety and Prevention Measures

Ventilation and Fume Extraction Management

Monitoring and Supervision

Emergency Procedures and First Aid

Cleaning Up and Waste Disposal

Final Inspection and Sign-off

Hazardous Substances

Welding Fumes

Ozone

Nitrogen Oxides

Metal Fume (e.g., Chromium, Nickel)

Argon

Induction Record

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