Work Activities · 7 checks · 1 critical

Hot Works
safety audit checklist

Welding, cutting, grinding, permits, fire watch, controls.

Every check below says what good looks like, when it passes, the regulation or HSE guidance it rests on and the defects that usually fail it. Critical checks are marked: a fail on one of those stops the activity.

  1. 1.
    Hot work permit issued and displayed
    Critical: a fail stops the work
    What to look forPermit issued by trained Permit Issuer specifying: location, task, persons, start/end times, controls, fire watch arrangements. Time-limited (typically 4 hours max, never longer than 1 shift). Displayed at work area. Insurance / property requirements (FPA RC7) often dictate format. Closed out at end of works after fire watch.
    Acceptable whenRegulatory Reform (Fire Safety) Order 2005, fire risk assessment for hot works. FPA Joint Code of Practice on Fire Prevention on Construction Sites (current 9th edition). Permit specifies controls AND closes out only after post-work fire watch.
    StandardRR(FS)O 2005. Joint Code of Practice (FPA, 9th edition). HSG168, Fire safety in construction.
    Common defectsNo permit issued, works in progressPermit time-expired but works continuingPermit issued for whole day (>4 hours), no rolling checkPermit not closed out after fire watchIssuer untrained / not authorised
  2. 2.
    Fire watcher in attendance
    What to look forDedicated fire watcher (not the operative doing the work) present throughout AND for fire-watch period after, minimum 60 minutes after work stops, longer where insurance requires (often 2hrs FPA standard). Watcher trained on extinguishers, has comms (radio/phone), knows escape routes and alarm activation.
    Acceptable whenRR(FS)O 2005. FPA Joint Code of Practice, fire watcher attends during AND for minimum 60 minutes (often 2 hours per insurance) after hot work. Trained on extinguisher use and alarm raising.
    StandardRR(FS)O 2005. FPA Joint Code of Practice (9th ed). HSG168.
    Common defectsOperative is also the fire watcher, concurrent taskFire watcher leaves immediately at end of work60 min watch shortened to 15 min "for the kettle"Watcher not trained / never used extinguisherNo comms, alarm cannot be raised remote from welfare
  3. 3.
    Fire extinguisher within 2m of works
    What to look forSuitable extinguisher (typically CO2 9kg or dry powder/water mist) within 2m of hot work, for cutting/welding metals CO2 preferred. In service date (annually inspected, replaced/refilled per BS 5306). Not blocked. Operative briefed on use. Extra extinguisher on adjacent levels for upward-spreading sparks.
    Acceptable whenRR(FS)O 2005 + BS 5306-3:2017 (commissioning, inspection and maintenance) + BS 5306-8 (selection and installation). FPA Joint Code, extinguisher within 2m of works. Annual inspection by competent person.
    StandardRR(FS)O 2005. BS 5306-3:2017 & 5306-8:2023. BS EN 3-7:2004+A1:2007 (portable extinguishers). FPA Joint Code.
    Common defectsExtinguisher >2m / round a corner from worksOut of inspection date (>12 months)Wrong type for hazard (water on electrics)Pressure indicator showing red, discharged or leakedOperative not trained, uses wrong technique
  4. 4.
    Combustibles cleared or protected with fire blankets
    What to look forAll combustibles within 10m removed; what cannot be removed protected with fire blanket (BS 6575) or proprietary welding curtain. Floor below covered with non-combustible mat to catch slag. Voids/penetrations sealed before hot works begin. Particular attention to insulation, cabling, gas lines, fuel.
    Acceptable whenFPA Joint Code, minimum 10m clearance of combustibles around hot works (where practicable); fire-resistant covering otherwise. Hazardous areas (paint stores, fuel), no hot works without further controls.
    StandardRR(FS)O 2005. FPA Joint Code (9th ed). BS 6575:1985 (fire blankets). HSG168.
    Common defectsInsulation against the work area, slag rolls onto itFire blanket draped but gaps below catching sparksFloor sealant/timber below not protectedHot works above suspended ceiling, sparks fall into voidsCombustibles not relocated, just shifted to next bay
  5. 5.
    Smoke detection locally isolated with permit
    What to look forWhere in occupied building, local smoke detector zone isolated by approved person to prevent nuisance alarms. Isolation logged, time-bound, restored at end of permit. Building responsible person (FRA Designated Person) informed. Adjacent zones still active so genuine fire still detected.
    Acceptable whenRR(FS)O 2005, fire detection must remain effective. Isolation only by trained person, only the smallest zone needed, restored immediately at end of works. Recorded in fire log book.
    StandardRR(FS)O 2005. BS 5839-1:2017 (fire detection in non-domestic premises). FPA Joint Code.
    Common defectsWhole building system isolated (not just affected zone)Isolation not logged, left isolated overnightBuilding responsible person not informedNo alternative detection (manual call point, watcher) during isolationPlastic bag over detector, cuts off all detection in that head
  6. 6.
    Post-work fire watch period defined (60 min minimum)
    What to look forPermit specifies fire watch duration, minimum 60 mins after work ends, increased to 2 hours where the insurer/FPA Joint Code requires. Fire watcher physically present and attentive (not on phone/leaving early). Final inspection of all surfaces touched. Adjacent voids/floors checked.
    Acceptable whenFPA Joint Code of Practice (9th ed), fire watch minimum 60 minutes after hot work ends; insurance/property may require 120 minutes. Adjacent areas, voids, opposite face of partition all checked.
    StandardRR(FS)O 2005. FPA Joint Code (9th ed). HSG168.
    Common defectsFire watcher leaves at end of work, no post-work watchWatch only 15-30 minutesAdjacent voids / opposite side of wall not checkedWatcher distracted, phone, second taskPermit closed before fire watch even started
  7. 7.
    Correct PPE worn (welding mask, gauntlets)
    What to look forWelding helmet/face shield with correct shade lens (DIN 9-13 typical for arc welding, DIN 4-8 gas/oxy-cutting). Long-sleeve flame-resistant clothing covering arms/legs (no synthetics). Welding gauntlets (EN 12477 Type B for arc, Type A for heavy duty). Leather apron/spats for heavy work. RPE for fume.
    Acceptable whenPPE at Work Regs 1992. EN 175 (welding helmets), EN 169 (filters), EN 12477 (welding gloves), EN ISO 11611 (welding clothing). Fume controls per COSHH (ventilation, on-tool extraction, RPE).
    StandardPPE at Work Regs 1992. EN 175, EN 169, EN 12477, EN ISO 11611. COSHH 2002 (welding fume reclassified Group 1 carcinogen, IARC).
    Common defectsSynthetic hi-vis ignites/melts onto skinNo RPE for welding fume (now classed as carcinogen)Wrong shade lens, eye flash injuriesBare forearms, arc burn from reflected UVLightweight gloves on heavy stick welding

Questions people ask

How often should a hot works audit be done?

Weekly is the common rhythm for a live site, plus whenever the work, the plant or the people change and after any incident or near miss. What matters is that it is scored, recorded, dated and the actions are closed out, not the exact frequency. Guidance, not legal advice.

What is the difference between a safety audit and an inspection?

An inspection looks at the site. An audit checks the system as well: is the paperwork there, do the people know it, is what was promised actually happening. On a small site the words blur, and that is fine. The checks below cover both.

What happens with a failed item?

A corrective action with an owner and a date, and a photo of the fail so nobody argues later. 1 of the 7 checks here are marked critical: a fail on one of those stops that activity until it is put right.

Who should carry out the audit?

A competent person, and where possible not the person whose work is being looked at. The site manager auditing the site manager's housekeeping is better than nothing, but a visiting supervisor or the SHEQ lead sees what the regular eye has stopped noticing.

Is a site safety audit a legal requirement?

The Management of Health and Safety at Work Regulations 1999 require arrangements for monitoring your health and safety measures (regulation 5), and CDM 2015 requires every contractor to plan, manage and monitor the work under their control (regulation 15). A recorded, scored audit is how you show that is happening. Guidance, not legal advice.

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