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Metal Fabrication›SWMS

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.

$35 AUD✓ Instant Download Available

SWMS variants reference your state's WHS legislation. Instant download after payment.

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

HazardConsequenceLikelihood
Fire ignition of flammable or combustible materials by sparks and slagStructural fire, property destruction, fatalitiesPossible
Explosion from ignition of flammable vapours or gasesFatal explosion, severe burns, building collapseUnlikely
Delayed fire ignition after hot work completionUndetected fire, significant property damage, injuriesPossible
Welding fume and smoke in non-ventilated areasRespiratory distress, smoke inhalationLikely
Burns from hot surfaces, sparks, and molten metalSecond and third degree burnsLikely
Fire suppression system activation causing damageWater damage, production interruptionUnlikely

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.

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