Hot Work SWMS

Hot work — welding, cutting, grinding, and brazing — generates ignition sources that can cause catastrophic fires and explosions when performed near flammable materials or contaminated atmospheres. The WHS Regulation 2025 classifies work in or near a contaminated or flammable atmosphere as high risk construction work requiring a SWMS. This template covers hot work permit procedures, fire watch protocols, and atmospheric testing mapped to applicable codes of practice effective 1 July 2026 under Section 26A.

Legal Requirements

regulation

WHS Regulation 2025 Part 4.4 — High Risk Construction Work

hrcw category

Work in or near a contaminated or flammable atmosphere

code of practice

Welding Processes Code of Practice (binding 1 July 2026 under Section 26A)

section 26a binding

Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.

Hazards

Hazard	Consequence	Likelihood
Fire ignition of nearby combustible materials from sparks, slag, or molten metal	Structural fire, burns, fatalities	Likely
Explosion from flammable gas or vapour ignition	Fatal blast injuries, structural damage	Unlikely
Toxic fume inhalation — welding fume, galvanised steel zinc oxide, cadmium	Metal fume fever, chronic respiratory disease, cancer	Likely
UV radiation and arc eye from welding operations	Corneal burns, temporary blindness, skin burns	Possible
Burns from contact with hot metal, sparks, and molten material	Severe burns, scarring	Possible

Controls (Hierarchy of Controls)

Eliminate hot work by using mechanical connections, adhesives, or prefabricated assemblies where feasible

Implement a hot work permit system requiring sign-off before each hot work task commences

Conduct atmospheric testing for LEL before hot work in areas that may contain flammable gases or vapours

Clear all combustible materials within a 10-metre radius or protect with fire-resistant blankets and screens

Station a fire watch with extinguisher for the duration of hot work plus 30 minutes after completion

Provide local exhaust ventilation or forced ventilation to control welding fume at the source

Ensure welders wear appropriate PPE — auto-darkening helmet, fire-resistant clothing, leather gloves

Recent Prosecutions

Hot work fire incidents (multiple jurisdictions)$50,000–$250,000 (various cases)

Multiple construction site fires caused by hot work without permits, inadequate combustible clearance, and no fire watch. Several resulted in total structure loss during fit-out.

2024 — Safe Work Australia Hot Work Incident Reports

What Your SWMS Must Include

✓Hot work permit template with atmospheric testing results, combustible clearance check, and fire watch sign-off

✓Fire watch procedure — duration, equipment, competency requirements, and escalation protocol

✓Atmospheric testing procedure for areas with potential flammable gas accumulation

✓Welding fume control measures including ventilation type and respiratory protection selection

✓Emergency response procedure including fire extinguisher locations and evacuation routes

Need a compliant Hot Work SWMS?

Our WHS consultants develop hot work SWMS with permit systems and fire watch procedures that satisfy regulator expectations and insurance requirements.