Welding & Cutting Safety Checklist

What is a hot work permit checklist? A hot work permit checklist is a safety authorization form required by OSHA 1910.252 and NFPA 51B before any welding, cutting, or other spark-producing operation. Hot work causes approximately 4,300 industrial fires annually. This checklist ensures proper fire prevention, ventilation, PPE, and fire watch procedures for safe welding and cutting operations.

  • Industry: Construction / Manufacturing
  • Frequency: Each hot work operation / Daily
  • Estimated Time: 15-20 minutes
  • Role: Welder / Fire Watch / Safety Officer
  • Total Items: 47
  • Compliance: OSHA 1910.252 (Welding, Cutting, Brazing), OSHA 1926.352-354 (Construction), NFPA 51B (Hot Work), AWS Z49.1, HSE Guidance (UK)

Area Preparation & Fire Prevention

Per OSHA 1910.252(a) and NFPA 51B, prepare area to prevent fire.

  • Combustibles removed within 35 feet?
  • Immovable combustibles protected with fire blankets?
  • Floors swept clean of combustible debris?
  • Floor/wall openings covered to prevent sparks?
  • Ducts and conveyor systems protected?
  • Fire sprinklers operational (if equipped)?
  • Appropriate fire extinguisher within 10 feet?
  • Fire extinguisher fully charged and inspected?
  • Fire alarm/notification system identified?

Enclosed Spaces & Confined Areas

Special precautions for welding in confined/enclosed spaces per OSHA 1910.252(b).

  • Work in enclosed or confined space?
  • Confined space permit obtained (if applicable)?
  • Adequate ventilation provided?
  • Local exhaust/fume extraction in place?
  • Atmosphere tested (LEL, O2)?
  • Continuous air monitoring during work?
  • Attendant posted outside confined space?
  • Rescue equipment available?

Equipment Inspection

Verify all welding/cutting equipment is in safe condition.

  • Welding equipment properly grounded?
  • Cables/leads free of damage, proper insulation?
  • All electrical connections tight?
  • Electrode holder in good condition?
  • Gas regulators in good condition?
  • Gas hoses free of leaks and damage?
  • Flashback arrestors installed?
  • Gas cylinders secured upright?
  • Valve caps on cylinders not in use?
  • Leak test performed on gas connections?

Personal Protective Equipment

Verify proper PPE per OSHA 1910.252(b)(2).

  • Welding helmet with proper shade lens?
  • Safety glasses under helmet?
  • Face shield for grinding/chipping?
  • Leather welding gloves worn?
  • Flame-resistant clothing worn?
  • Leather apron/sleeves (as needed)?
  • Leather work boots (no open holes)?
  • Hearing protection (if needed)?
  • Respiratory protection (if needed)?

Fire Watch Requirements

Per OSHA 1910.252(a)(2)(iii), fire watch required when combustibles are nearby.

  • Fire watch personnel assigned?
  • Fire watch trained in duties and extinguisher use?
  • Fire watch equipped with extinguisher?
  • Fire watch posted with clear view of work?
  • Fire watch will continue 30+ minutes after work?
  • Communication method established?
  • Emergency contact numbers posted?

PPE Compliance Verification

Personal protective equipment inspection

  • Hard hats worn in required areas?
  • Safety glasses/goggles worn as required?
  • High-visibility vests worn?
  • Steel-toe boots worn by all workers?

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