Hot Work JSA – Job Safety Analysis
1. Introduction
Hot work refers to activities such as welding, cutting, brazing, soldering, and grinding that generate heat, sparks, or flames. These jobs are essential in construction, fabrication, and maintenance but present significant risks such as fire, explosion, burns, toxic fumes, and eye injuries.
A Job Safety Analysis (JSA) systematically identifies these hazards, evaluates risk, and establishes control measures to protect workers, equipment, and property.
2. Purpose of This JSA
The objectives are to:
- Prevent fire and explosion hazards during hot work.
- Protect workers from burns, sparks, and radiation.
- Control exposure to toxic fumes and gases.
- Ensure compliance with OSHA, NFPA, and other safety standards.
- Promote hazard awareness and safe work practices.
3. Applicable Standards & References
- OSHA 29 CFR 1910.252 – Welding, Cutting, and Brazing
- OSHA 29 CFR 1926 Subpart J – Welding and Cutting in Construction
- NFPA 51B – Standard for Fire Prevention During Welding, Cutting, and Other Hot Work
- ISO 3834 – Quality Requirements for Welding
- Company Hot Work Permit System
4. Scope of Work
This JSA covers:
- Electric arc welding
- Oxy-fuel gas cutting/welding
- Grinding operations
- Torch cutting and plasma cutting
- Fabrication and repair involving hot work
5. Step-by-Step JSA Process for Hot Work
Step 1: Job Breakdown
- Pre-job planning and hot work permit issuance.
- Inspection of work area and equipment.
- Removal of combustible materials or installation of fire blankets.
- Setting up welding/cutting/grinding equipment.
- Performing welding, cutting, or grinding.
- Fire watch and post-work inspection.
- Equipment shutdown and housekeeping.
Step 2: Hazard Identification
Hot work hazards include:
- Fire and explosion from sparks or molten metal.
- Burns from contact with hot surfaces or spatter.
- Eye injuries from sparks, ultraviolet (UV), or infrared (IR) radiation.
- Respiratory hazards from welding fumes and gases.
- Noise from grinding and cutting operations.
- Electrical shock from arc welding equipment.
- Flying debris from grinding wheels.
Step 3: Risk Assessment Table
| Task | Hazard | Potential Consequence | Risk Rating | Control Measures |
|---|---|---|---|---|
| Pre-job planning | No hot work permit | Fire, non-compliance | High | Implement permit system |
| Work area inspection | Combustible material nearby | Fire | High | Remove or shield combustibles |
| Equipment setup | Faulty hoses or cables | Explosion, electrocution | High | Inspect before use |
| Welding/cutting | Sparks, molten metal | Burns, fire | High | PPE, fire blankets, fire watch |
| Grinding | Flying debris | Eye injury | High | Safety goggles, face shield |
| Post-job inspection | Hidden smoldering fire | Fire outbreak later | High | 30-minute fire watch |
6. Control Measures
A. Engineering Controls
- Use fire-resistant screens and blankets around the work area.
- Provide adequate ventilation or local exhaust systems.
- Use ground-fault circuit interrupters (GFCIs) for electrical equipment.
- Maintain equipment in good condition with regular inspections.
B. Administrative Controls
- Implement a Hot Work Permit System.
- Assign a fire watch during and after hot work.
- Establish an exclusion zone with signage and barriers.
- Train workers in safe use of hot work equipment.
- Enforce no hot work in hazardous locations (confined spaces, near flammable storage) unless special precautions are taken.
C. Personal Protective Equipment (PPE)
- Welding helmet with proper shade lens.
- Safety goggles and face shield for cutting/grinding.
- Fire-resistant (FR) clothing.
- Heat-resistant gloves.
- Safety shoes with metatarsal protection.
- Hearing protection.
- Respiratory protection if ventilation is inadequate.
7. Roles & Responsibilities
- Site Manager: Authorizes hot work permit and ensures resources.
- Supervisor: Ensures compliance with hot work safety procedure.
- Hot Work Operator: Performs welding, cutting, or grinding safely.
- Fire Watcher: Monitors sparks, ready with fire extinguisher.
- Safety Officer: Inspects work area, verifies controls.
8. Emergency Preparedness
- Fire extinguishers (CO₂, dry chemical) must be within 15 meters.
- Emergency evacuation routes clearly marked.
- First aid kits available for burns and eye injuries.
- Emergency contact numbers displayed.
- Rescue plan in place for confined space hot work.
9. Best Practices for Hot Work Safety
- Never perform hot work without a valid permit.
- Conduct gas testing for confined spaces.
- Keep flammable gases and materials at least 10 meters away.
- Check for hidden combustibles behind walls and partitions.
- Allow at least 30 minutes of fire watch after hot work.
- Replace damaged hoses, cables, or regulators immediately.
- Use only approved grinding wheels with protective guards.
10. Sample JSA Form – Hot Work (Welding, Cutting, Grinding)
Job Title: Hot Work – Welding, Cutting, Grinding
Location: ________________________
Date: ________________________
Supervisor: ________________________
| Task Step | Hazard | Control Measure | PPE Required | Responsible Person |
|---|---|---|---|---|
| Permit issuance | Fire hazard | Hot work permit required | Helmet, vest | Supervisor |
| Equipment setup | Faulty hoses/cables | Inspection, maintenance | Gloves | Operator |
| Welding/cutting | Sparks, UV rays | Screens, shields | Helmet, FR clothing | Operator |
| Grinding | Flying debris, noise | Machine guard, face shield | Goggles, ear plugs | Operator |
| Fire watch | Hidden fire | Fire extinguisher ready | Helmet | Fire watcher |
11. Conclusion
A well-prepared Hot Work JSA reduces risks of fire, injury, and property damage. The key to hot work safety lies in strict adherence to permit systems, proper PPE use, engineering controls, and constant vigilance during and after the work.
✅ Final Safety Reminder:
“Every spark has the potential to ignite a disaster — control it before it controls you.”
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