🔥 Hot Work Permit Playbook
Hot work — welding, cutting, grinding — starts fires. A permit system ensures someone has inspected the area, controlled combustibles, and assigned a fire watch. No permit, no hot work.
Why This Matters
| Without Hot Work Permits | With Hot Work Permits |
|---|---|
| Fires from sparks and slag igniting combustibles | Pre-work inspection catches hazards before ignition |
| No fire watch — no one watching for flames | Fire watch during and after work catches smoldering fires |
| Undocumented hot work — no traceability | Permit trail: who, where, when, what was checked |
| Construction fires cause millions in damage | Controlled process reduces fire risk significantly |
| Insurance and code requirements missed | Compliance with NFPA 51B and insurance requirements |
NFPA 51B
NFPA 51B (Standard for Fire Prevention During Welding, Cutting, and Other Hot Work) requires a permit program for hot work in areas where combustibles are present or could be introduced.
Roles and Responsibilities
| Role | Responsibilities |
|---|---|
| Permit Authorizer | Issue permits after inspection; verify conditions; close permit |
| Hot Work Performer | Obtain permit before work; follow permit conditions; notify when done |
| Fire Watch | Monitor during work and 30–60 min after; have extinguisher; trained |
| Superintendent / Safety | Ensure permit process is followed; audit compliance |
What Constitutes Hot Work
| Activity | Hot Work? |
|---|---|
| Welding | Yes |
| Cutting (torch, plasma, abrasive) | Yes |
| Brazing | Yes |
| Grinding (sparks) | Yes |
| Soldering (high-temp) | Yes — in some cases |
| Torch-applied roofing | Yes |
| Heat treating | Yes |
| Thawing pipes | Yes — open flame |
When Permits Are Required
| Scenario | Permit Required? |
|---|---|
| Near combustibles (wood, paper, plastics, flammables) | Yes |
| In confined spaces | Yes |
| Near fire suppression systems (that may be impaired) | Yes |
| On combustible construction | Yes |
| Designated hot work area (dedicated, fire-resistant) | Often no — per site policy |
| Open field, no combustibles | Site policy — many still require for documentation |
When in doubt: Get a permit.
Permit Workflow
Phase 1: Request
- Who: Hot work performer or foreman
- What: Location, type of work, duration, performer name
- When: Before work begins
Phase 2: Inspection
Permit authorizer conducts pre-work inspection:
| Check | Verify |
|---|---|
| Combustibles | Removed, covered with fire-resistant material, or wet down |
| Floors | Swept clean; no debris within 35 feet |
| Walls, ceilings | Combustibles covered or removed |
| Openings | Covers in place to prevent sparks traveling |
| Fire extinguisher | Present, charged, within 50 feet |
| Sprinklers | Active (or impairment documented) |
| Ventilation | Adequate for fumes |
| Personnel | Fire watch assigned and trained |
Phase 3: Approval
- Authorizer signs permit
- Performer acknowledges conditions
- Fire watch assigned and briefed
- Permit posted at work location
Phase 4: Fire Watch
- During work: Fire watch monitors continuously
- After work: Fire watch remains 30–60 minutes (minimum 30)
- Fire watch has: Extinguisher, ability to call 911, knowledge of location
Phase 5: Post-Work Monitoring
- Fire watch checks area for smoldering
- Final walk-through 30–60 min after work stops
- No smoke, sparks, or heat before leaving
Phase 6: Close
- Authorizer or fire watch conducts final check
- Permit closed — signed, dated, retained
- Retention: Typically 1 year (check local/code requirements)
Pre-Work Inspection Checklist
| Item | Status |
|---|---|
| Combustibles removed or protected within 35 feet | ☐ |
| Floors swept; no dust, debris | ☐ |
| Walls, ceilings protected if combustible | ☐ |
| Openings covered (ducts, cracks) | ☐ |
| Fire extinguisher present and charged | ☐ |
| Sprinklers active (or impairment managed) | ☐ |
| Ventilation adequate | ☐ |
| Fire watch assigned | ☐ |
| Fire watch trained | ☐ |
| Workers aware of emergency procedures | ☐ |
Fire Watch Requirements
| Requirement | Detail |
|---|---|
| During work | Continuous monitoring — no other duties |
| After work | 30 minutes minimum (60 min for high-risk; check NFPA 51B) |
| Equipment | Fire extinguisher; means to call 911 |
| Training | Knows how to use extinguisher; knows location; knows emergency procedures |
| Same area | Fire watch remains in area where hot work occurred |
Fire Watch Is Not Optional
The majority of hot work fires start after the work is done — from smoldering debris. Fire watch during and after is critical.
Fire Watch Responsibilities
| Responsibility | Action |
|---|---|
| Monitor | Watch for sparks, flames, smoke — continuous attention |
| Extinguish | Use extinguisher on small fires |
| Alert | Call 911 for fires beyond incipient stage |
| Remain | Stay 30–60 min after work; re-check for smoldering |
| Report | Notify authorizer of any issues; note on permit |
Documentation and Record Retention
| Document | Retain |
|---|---|
| Permit (signed, dated) | 1 year (NFPA 51B); longer if required by owner/insurance |
| Inspection checklist | With permit |
| Fire watch log (if separate) | With permit |
App Integration Tips
BLDR Pro — Permit Documentation
Use BLDR Pro to create, store, and track hot work permits. Attach pre-work inspection photos — combustible conditions, extinguisher placement, protected areas. Document fire watch assignment and close-out. Pull permit history for audits or post-fire investigations.
Photo Verification
Take before-and-after photos: area before work (showing controls), area after final check. Timestamped photos prove you followed the process.
Metrics to Track
| Metric | Target | Frequency |
|---|---|---|
| Permits issued vs. hot work activities | 100% — every hot work has permit | Daily |
| Fire watch compliance | 100% — fire watch present and trained | Per permit |
| Hot work incidents | Zero | Per incident |
| Near-misses (sparks, small fires) | Document and trend | Monthly |
| Permit close-out rate | 100% closed same day | Daily |
Common Mistakes
| Mistake | Problem | Fix |
|---|---|---|
| Starting without permit | No inspection; no fire watch | Permit before ignition — no exceptions |
| Skipping fire watch | No one watching; smoldering fire grows | Fire watch mandatory; assign before permit issued |
| Leaving too soon | Fire starts after worker leaves | 30–60 min post-work monitoring; documented |
| No pre-work inspection | Combustibles present; fire ignites | Checklist every time; authorizer signs |
| Untrained fire watch | Doesn't know what to do | Train before assigning; document training |
| Permit not closed | No record of completion; no final check | Close permit with final inspection; retain |
Troubleshooting
"We need to weld now — we don't have time for a permit"
- A 5-minute permit process prevents a 5-hour fire response. No permit = no hot work.
- Keep permit forms and authorizer readily available so the process is fast.
"We're in a designated hot work area — do we need a permit?"
- Designated areas (e.g., fabrication shop with fire-resistant floor) may be exempt per written policy.
- Document the designated area and policy. If combustibles can be introduced, permit applies.
"Fire watch has other duties"
- Fire watch must focus on fire prevention — no other tasks during the watch.
- If you can't spare someone for fire watch, you can't do hot work. Reschedule.
"Sub did hot work without a permit"
- Stop their work immediately. Require permit process.
- Add to sub pre-construction meeting: "No hot work without GC permit approval."
- Audit subs regularly.
Related Resources
| Resource | Link |
|---|---|
| Incident Reporting Playbook | Incident Reporting |
| Site Safety Inspection Playbook | Site Safety Inspections |
| JSA/JHA Playbook | JSA/JHA Process |
| Safety Compliance Guide | Compliance Guide |
| Fire Prevention | Fire Safety |