Hot work operations — including welding, cutting, brazing, soldering, grinding, and torch use — are among the leading causes of workplace fires. NFPA reports that fire departments respond to an average of 4,580 structure fires per year caused by hot work activities. OSHA 29 CFR 1910.252 and NFPA 51B establish the regulatory framework for fire prevention during hot work, requiring area inspection, written authorization (preferably a permit), fire watch, and combustible clearance. A thorough pre-work inspection and a disciplined permit system are the primary defenses against hot work fires. This guide covers all inspection requirements with a free downloadable checklist.
Free Hot Work Permit Inspection Checklist
Download our Word document checklist covering pre-work area inspection, fire prevention controls, fire watch requirements, and post-work monitoring per OSHA and NFPA 51B.
Download Checklist (.docx)Regulatory Framework
OSHA Requirements
- 1910.252 (General Industry): Fire prevention and protection for welding, cutting, and brazing. Requires area inspection before hot work, authorization (preferably written permit), combustible clearance of 35 feet, fire watch for at least 30 minutes post-work, and appropriate PPE. References NFPA 51B for elaboration of fire prevention responsibilities.
- 1926.352 (Construction): Fire prevention during welding and cutting in construction. Prohibits hot work in areas with impaired sprinklers or flammable atmospheres. Requires fire extinguisher within immediate area and a fire watch where combustible conditions exist.
- 1910.146 (Confined Spaces): Hot work inside permit-required confined spaces requires both a hot work permit and a confined space entry permit. Additional atmospheric monitoring for flammable gases required.
- EPA RMP (40 CFR 68): Risk Management Program-covered facilities must maintain written hot work permits documenting all fire prevention controls. Permits must be retained on file until work is completed.
NFPA 51B — Fire Prevention During Welding, Cutting, and Other Hot Work
- Permit Authorizing Individual (PAI): Designated person who inspects the hot work area using a checklist, authorizes the work, and issues the permit. The PAI must verify all fire prevention measures are in place before work begins.
- Fire watch duration: Minimum 60 minutes after hot work completion (NFPA 51B 2019 edition). PAI may extend to up to 3 hours in higher-risk situations. This exceeds OSHA’s 30-minute baseline.
- Designated hot work areas: Permanent locations equipped for hot work (e.g., welding shops) with combustibles removed and fire protection in place. Permits generally not required in properly maintained designated areas.
- Hot work scope: Applies to any operation involving open flames or producing heat and/or sparks, including welding, cutting, brazing, soldering, grinding, thawing, and heat treatment.
Hot work fire statistics: According to NFPA, 57% of hot work structure fires occur in non-home properties. The primary cause of hot work fires is failure to maintain adequate clearance from combustibles and failure to post a fire watch. Hot work sparks can travel up to 35 feet horizontally and much further when falling through floor openings, wall penetrations, or ductwork. Heat transfer through shared walls and metal pipes can ignite materials on the opposite side.
Part 1: Pre-Work Area Inspection
| Inspection Item | What to Check |
|---|---|
| 35-foot combustible clearance | All movable combustibles removed to at least 35 feet from hot work location per 1910.252(a)(2)(i). Immovable combustibles covered with fire-resistant blankets, curtains, or guards. Floor swept clean of combustible debris (shavings, paper, textile fibers). No combustible dust accumulation on surfaces within the zone. |
| Wall, floor, and ceiling openings | Openings in walls, floors, and ceilings within 35 feet sealed or protected per 1910.252(a)(2)(i)(D). Cracks and gaps in fire barriers covered. Ducts, pipes, and conduit penetrations that could carry sparks to concealed spaces sealed with fire-resistant material. Opposite side of shared walls inspected for combustibles. |
| Flammable atmosphere | No flammable vapors, gases, or dust present per 1926.352. Atmospheric monitoring performed if flammable materials are stored or used in the area. LEL below 10% of lower explosive limit. Adequate ventilation in place. Containers of flammable liquids closed and secured. |
| Fire suppression systems | Fire sprinkler system in service and not impaired per 1926.352. Sprinkler heads not obstructed or blocked within 18 inches. If sprinklers temporarily impaired, hot work prohibited until restored or equivalent fire protection provided. Fire alarm pull stations accessible. |
| Smoke detection coordination | Smoke detectors in the immediate hot work area identified. Detectors temporarily covered or placed in test mode if hot work will generate smoke (coordinate with fire alarm monitoring company). Documented plan to restore detectors immediately after work completion. Notification to building management and fire watch team. |
Part 2: Permit, Equipment & PPE
| Inspection Item | What to Check |
|---|---|
| Hot work permit issued | Written permit issued by authorized Permit Authorizing Individual (PAI). Permit documents: date, time, location, type of hot work, name of operator, fire watch personnel, fire prevention measures in place, permit expiration time. Permit posted at the work location. All required signatures obtained before work begins. |
| Fire extinguisher | Appropriate fire extinguisher (minimum 2A:10BC or as specified) positioned within immediate reach of the hot work location. Extinguisher fully charged with current inspection tag. Operator and fire watch trained in extinguisher use. Additional extinguishers available on all levels where sparks may travel. |
| Welding/cutting equipment | Equipment in safe operating condition. Electrical cables, hoses, and connections inspected for damage. Ground clamp securely attached near work piece. Gas cylinder valves, regulators, and flashback arrestors functioning. Torch tip appropriate for the work. Equipment meets OSHA 1910.254 (arc welding) or 1910.253 (gas welding) requirements. |
| Personal protective equipment | Welding helmet with correct shade filter lens (arc: shade 10–14, gas: shade 4–8). Flame-resistant clothing (no synthetic materials that can melt). Leather welding gloves. Safety-toed boots. Hearing protection if noise exceeds 85 dB. Respiratory protection if ventilation is insufficient per 1910.252(c). |
| Welding screens and barriers | Welding screens or curtains positioned to protect nearby workers from arc flash, sparks, and UV radiation per 1910.252(b)(2)(iii). Screens rated for welding use (not ordinary curtains). Screens stable and positioned to block all lines of sight to the arc from occupied areas. Warning signs posted at area boundaries. |
Part 3: Fire Watch & Post-Work Monitoring
| Inspection Item | What to Check |
|---|---|
| Fire watch assigned | Dedicated fire watch person assigned per 1910.252(a)(2)(iii). Fire watch has no other duties during hot work. Fire watch trained in fire extinguisher use and emergency alarm procedures. Fire watch has authority to stop hot work if hazardous conditions develop. Fire watch can see the entire hot work area and areas where sparks may travel. |
| Fire watch equipment | Fire watch has fire extinguisher within immediate reach. Communication device (radio, phone) available for emergency notification. Flashlight available for inspecting concealed areas. Fire watch log/checklist for recording observations. Access to areas above, below, and adjacent to hot work for monitoring. |
| Post-work monitoring | Fire watch maintained for minimum 30 minutes (OSHA) or 60 minutes (NFPA 51B) after hot work completion. Extended monitoring (up to 3 hours) in higher-risk areas per PAI determination. Thorough inspection of hot work area, adjacent areas, and concealed spaces (wall cavities, ceiling voids, ductwork). No smoldering or hot spots detected. Smoke detectors restored to service. |
| Post-work documentation | Fire watch completion time recorded on permit. Fire watch person signs off confirming no fire hazards observed. Permit closed and filed per company retention policy. Any incidents, near-misses, or issues documented. Smoke detectors and fire alarm system restored and verified operational. |
| Multi-level monitoring | Areas above and below the hot work location inspected for spark travel. Floor openings, pipe chases, and wall penetrations checked for smoldering. Fire watch coverage extends to all levels where sparks or heat may have traveled. No hot work debris (slag, electrode stubs) left on combustible surfaces. |
Fire watch duration comparison: OSHA 1910.252: minimum 30 minutes post-work. NFPA 51B (2019): minimum 60 minutes post-work, PAI may extend to 3 hours. Many insurers (FM Global, etc.): 60 minutes minimum, recommend longer for concealed spaces. Company policy: should match the most stringent applicable requirement. Best practice: extend fire watch whenever hot work is near concealed combustible spaces, involves cutting into walls or ceilings, or occurs in buildings with wood framing or combustible insulation.
Download the Free Checklist
Get our hot work permit inspection checklist in Word format. Covers all OSHA and NFPA 51B requirements for hot work fire prevention.
Download Checklist (.docx)Go digital with Ecesis. Issue and manage hot work permits digitally with Ecesis inspection software. Capture pre-work area photos, track fire watch sign-offs in real time, and automate permit expiration alerts. Integrate with confined space permits for combined operations. Generate compliance records for OSHA, NFPA, and insurance audits. Request a free demo.
Ecesis EHS Software
Inspections
Digital hot work permit checklists with pre-work area inspection, fire watch tracking, and post-work sign-off.
Incident Management
Report fire incidents, near-misses, and equipment failures with root cause analysis.
Compliance Calendar
Track fire extinguisher inspections, fire suppression system testing, and training due dates.
Task Management
Assign corrective actions for fire prevention deficiencies and track completion.
Chemical Management
Identify flammable and combustible materials near hot work areas using SDS data.
Training
Track hot work operator training, fire watch certifications, and PAI qualifications.
