Hot Work Permit SWMS

Hot work encompasses any operation that produces heat, sparks, or flame sufficient to ignite flammable or combustible materials. In metal fabrication, this includes welding, cutting, grinding, brazing, and soldering conducted outside dedicated welding areas or near flammable atmospheres. Hot work is one of the leading causes of industrial fires in Australia. The WHS Regulation 2025 requires a permit-to-work system for all hot work conducted near flammable or combustible atmospheres, with fire watch maintained during and after the work period. This template maps controls to the binding Welding Processes Code of Practice effective 1 July 2026 under Section 26A.

Legal Requirements

regulation

WHS Regulation 2025 Part 7.1 — Hazardous Chemicals and Part 4.4 — High Risk Construction Work

hrcw category

Work in or near a contaminated or flammable atmosphere

code of practice

Welding Processes (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 flammable or combustible materials by sparks and slag	Structural fire, property destruction, fatalities	Possible
Explosion from ignition of flammable vapours or gases	Fatal explosion, severe burns, building collapse	Unlikely
Delayed fire ignition after hot work completion	Undetected fire, significant property damage, injuries	Possible
Welding fume and smoke in non-ventilated areas	Respiratory distress, smoke inhalation	Likely
Burns from hot surfaces, sparks, and molten metal	Second and third degree burns	Likely
Fire suppression system activation causing damage	Water damage, production interruption	Unlikely

Controls (Hierarchy of Controls)

Issue a hot work permit for every hot work task outside designated welding areas

Inspect the work area and all adjacent areas within 10 metres for combustible materials before issuing permit

Remove or protect all combustible materials within the hot work zone including materials on the opposite side of walls and floors

Assign a dedicated fire watch during hot work and for a minimum of 60 minutes after completion

Provide appropriate fire extinguishers within 5 metres of the hot work location

Test for flammable atmospheres using a calibrated gas detector before commencing hot work in any area with potential vapour or gas presence

Notify the fire alarm monitoring service before commencing hot work to prevent false alarm responses

Close the hot work permit only after the fire watch period is complete and the area is confirmed safe

Recent Prosecutions

Orica Australia Pty Ltd$1,200,000

Multiple safety failures including inadequate controls for hazardous work activities.

2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]

BI Australia Pty Ltd$400,000

Inadequate safety controls during fabrication work resulting in serious worker injuries.

2025 — SafeWork NSW v BI Australia Pty Ltd [2025]

What Your SWMS Must Include

✓Hot work permit template with pre-work inspection checklist

✓Combustible material identification and protection procedures

✓Fire watch assignment, duration, and handover procedures

✓Atmospheric testing requirements for areas with potential flammable vapours

✓Post-work area inspection and permit close-out procedure

Need a compliant Hot Work Permit SWMS?

Our WHS consultants build site-specific hot work permit systems that prevent fire, satisfy insurers, and meet WHS Regulation 2025 requirements.