Professional Documents
Culture Documents
FMDS1003 Hot Work Management
FMDS1003 Hot Work Management
Table of Contents
Page
List of Figures
Fig. 1. Hot work designated area ................................................................................................................... 6
Fig. 2. Hot work permit-required area with single hot work site .................................................................... 9
Fig. 3. Hot work permit-required area with multiple hot work sites ............................................................... 9
Fig. 4. Rooftop hot work permit-required area ............................................................................................. 11
Fig. 5. Elevated hot work permit-required area ........................................................................................... 11
Fig. 6. Hot work ignition source temperature vs. solid-fuel ignition temperature ........................................ 17
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10-3 Hot Work Management
Page 2 FM Global Property Loss Prevention Data Sheets
List of Tables
Table 1. Construction and Occupancy Factors for Determining Post-Work Fire Watch and Fire
Monitoring Periods .......................................................................................................................... 15
Table 2. Alternative Cold Work Methods ...................................................................................................... 18
1.0 SCOPE
This document provides recommendations for preventing hot work fires and explosions. The guidance within
this document is applicable to all facilities where hot work is conducted on a temporary or routine basis.
Refer to other FM Global data sheets for prevention of hot surface and open-flame ignition source hazards
associated with heated processes or utility equipment such as ovens/dryers, furnaces, kilns, and boilers.
1.1 Hazards
1.2 Changes
July 2018. Interim revision. A sample Hot Work Permit was updated (Appendix D). Construction and
occupancy factors for post-work fire watch and monitoring periods (page 3) were added.
2.1 Introduction
Improperly managed hot work remains a leading cause of large fires and explosions. Based on a review of
FM Global loss history, the following conclusions were drawn regarding key factors in hot work losses:
A. Failing to identify and isolate combustible construction in the hot work area increases the likelihood and
severity of a hot work fire.
B. Failing to identify and isolate combustibles in a hot work high-risk area increases the likelihood and
severity of a hot work fire.
C. In-service fire protection systems significantly reduce the severity of a hot work fire.
D. The overwhelming majority of hot work fires occur while the work is being done or within 60 minutes
of completion, highlighting the importance of a fire watch both during and following hot work.
The primary focus of a hot work management program should be on pursuing cold work alternatives or, failing
that, relocating the work to a hot work designated area. If hot work is unavoidable, it is vital to remove or
isolate combustible materials. Regardless of size, any hot work fire or explosion should be viewed as a failure
of the hot work management program.
The post-work fire watch and/or fire monitoring period should be considered a secondary layer of protection
against the uncertainty of identifying and controlling all combustible materials within the hot work area. The
appropriate post-work watch and monitoring duration requires judgment based on the factors present within
the hot work area, including confidence in being able to identify and remove or isolate combustible materials;
the type and quantity of combustible materials present within the hot work area (i.e., combustibles that could
be removed and are capable of smoldering or of a sufficient quantity to support a large uncontrolled fire);
and the presence of automatic fire protection. If the hot work area is unprotected (e.g., unsprinklered),
post-work watch and monitoring along with manual fire-fighting required precautions become more critical.
At no time should any length of post-work watch and monitoring be considered a substitute for properly
preparing and maintaining the hot work area or equipment. A hot work management process should always
begin with and focus on controlling combustibles in the hot work area.
H. Define the requirements for auditing the hot work management program, including scope and frequency.
I. Have the program endorsed by facility senior management.
2.2.1.1 When applicable, incorporate standard operating procedures (SOPs) for hot work management into
the facility’s International Organization for Standardization (ISO) certification. ISO certification requirements
often align with administrative controls recommended in Section 2.2, including policy statement, document
retention, management of change, and auditing.
2.2.1.2 When multiple categorized areas are present, ensure the appropriate fire watch and fire monitoring
periods are provided in each by incorporating the following administrative controls:
A. Clearly define the boundaries of each categorized area in the policy statement and procedures.
Preferably, develop a site plan and/or building plan showing the boundaries of the various categorized
areas.
B. Train permit authorizers and personnel performing hot work to recognize the boundaries of the
categorized areas, and how changes to the areas are communicated and updated.
2.2.2 Conduct initial and annual refresher training for all employees and contractors involved in the hot work
management program.
2.2.2.1 Train employees working in or inspecting hot work designated areas or production hot work areas
to maintain the work area free of combustible materials and to contain hot work ignition sources within the
work area.
2.2.2.2 At a minimum, train employees and contractors involved with hot work permitting (including permit
authorizers, personnel performing hot work, fire watches, and fire monitors) in the following subjects:
A. Implementation and control of required precautions, and how to escalate any problems identified with
the required precautions
B. Inspecting the hot work area for fire-safe conditions and, if a fire is detected, notifying emergency
contacts before making any attempt to extinguish the fire
C. Use of fire extinguishers or firefighting hose if expected to use this equipment in response to a fire
2.2.3 Retain hot work management records for program auditing. At a minimum, retain the following records:
A. Completed forms, including hot work designated area inspections and hot work permits
B. Reports on hot work fire and explosions, including root cause and corrective action to prevent a
reoccurrence
C. All hot work management program audit findings
2.2.4 Conduct audits of the hot work management program. Establish an audit frequency based on facility
conditions, such as previous audit findings and hot work-related fires and explosions. At a minimum, conduct
audits at least annually. Include the following in the audits:
A. Completed forms, including hot work designated area inspections and hot work permits from different
post-work categorized areas.
B. Training records for contractors and employees.
C. Incident log and investigation reports for hot work fires and explosions as well as near misses.
Determine the status of any resulting corrective actions.
D. Facility changes that may impact the hot work management program, hot work designated areas,
permitting procedures, or hot work high-risk areas (e.g., physical or personnel changes).
2.2.5 Manage contractors in accordance with Data Sheet 10-4, Contractor Management. Ensure contractors
are familiar with the facility-specific hazards and are supervised during their work.
A. Avoid hot work. Consider using an alternative cold work method. Refer to Section 3.1.3 for information
on alternative cold work methods.
B. Relocate the work to a hot work designated area protected in accordance with Section 2.4.
2.3.2 If hot work that requires a permit is unavoidable, use a hot work permit system meeting the requirements
of this data sheet and/or the local authority having jurisdiction, whichever is more stringent.
2.3.3 Maintain hot work equipment in good operation per the equipment manufacturer’s guidelines.
2.3.4 Ensure hot work equipment is properly installed and arranged prior to initiating work. For example,
provide appropriate electrical grounding for work surfaces to prevent stray currents during arc welding; protect
piping and hoses conveying flammable or shielding gases used for welding or cutting; and restrain
compressed gas cylinders used for welding or cutting.
2.3.5 When hot work is routinely conducted as part of production, protect the production area as a hot work
designated area in accordance with Section 2.4.
2.4 Hot Work Designated Areas (Hot Work Permit Not Required)
Metal cabinet
for combustibles
Hot
work
site
FM Approved welding
curtain at opening
0 t
(1 5 f
)
m
3
A. Employ temporary barriers, such as FM Approved welding curtains or blankets, to control ignition sources
at unprotected openings in the cutoff rooms (e.g., open doorways or partial wall heights or lengths). Provide
sufficient overlap and securement of the welding curtains or blankets. Label unprotected openings using
signage.
B. Maintain a minimum 35 ft (10 m) clear separation distance at the open sides of the cutoff room. Label
this separation distance using permanent marking (e.g., strips on the floor) and signage.
2.4.1.3 Construct cutoff rooms enclosing hot work designated areas of noncombustible construction. Install
wall and ceiling/roof building assemblies that contain only noncombustible building materials. FM Approved
Class 1 building materials are considered noncombustible.
2.4.1.4 Install facing materials on walls and ceilings that resist impact damage (e.g., corrugated steel
paneling). Limit the use of brittle materials that are prone to mechanical impact damage (e.g., gypsum board).
2.4.1.5 Seal joints between floors, walls, and ceilings/roofs to prevent hot work ignition sources from escaping
the designated area. Use FM Approved fire-stop materials.
2.4.2 Occupancy
2.4.2.1 Maintain hot work designated areas free of combustible, ignitable, and flammable materials. If required
for work, store combustible materials in metal cabinets, and ignitable and flammable materials in FM
Approved storage cabinets for flammable and combustible liquids.
2.4.2.2 Design and install HVAC systems per Data Sheet 7-78, Industrial Exhaust Systems. Incorporate the
following into the system design:
A. Provide a dedicated HVAC system serving the hot work designated area.
B. Use noncombustible ductwork and insulation.
C. If particulate filtration is required, use an FM Approved Class 1 air filter.
2.4.3 Protection
2.4.3.1 Provide automatic sprinkler protection within hot work designated areas when the cutoff room wall
or ceiling/roof assemblies contain combustible construction. Design and install sprinkler protection based on
the occupancy within the room.
2.4.3.2 Provide supplemental fire extinguishers within hot work designated area (i.e., in addition to those
extinguishers required by local codes). Ensure the extinguishers are rated and sized appropriately for the
hazard. Inspect, test, and maintain fire extinguishers per Data Sheet 2-81, Fire Protection System Inspection,
Testing, and Maintenance.
F. Conduct a final check of the hot work area for fire-safe conditions after the post-work fire watch and/or
fire monitoring periods have concluded. Preferably, have a permit authorizer conduct the final check;
however, fire watch and fire monitor personnel should be sufficiently trained to conduct the final check
as well. Maintain completed hot work permits for auditing per Section 2.2.3.
2.5.1.2 Verify hot work equipment is operable and arranged per Sections 2.3.3 and 2.3.4.
2.5.1.3 If the proposed work is to be conducted in a hot work high-risk area, additional required precautions
may be warranted due to the greater likelihood and/or consequence of fires or explosions. Refer to Section
2.5.2 for a discussion of several hot work high-risk areas/operations.
R Hot work
site
Hot work
area
R = 35 ft. (10 m)
H = 15 ft. (5 m)
Fig. 2. Hot work permit-required area with single hot work site
Multiple hot
R work sites
R
R = 35 ft. (10 m)
H = 15 ft. (5 m)
Fig. 3. Hot work permit-required area with multiple hot work sites
B. Contain hot work ignition sources using FM Approved welding pads, blankets, or curtains using the
appropriate application as discussed below:
1. Welding pads are intended for use where the hot work exposure is severe. FM Approved pads are
designed to resist burn-through and thermal conduction when positioned in close proximity to the hot work
site in a horizontal orientation and exposed to molten metal contact.
2. Welding blankets are intended for use where the hot work exposure is moderate. FM Approved blankets
are designed to resist burn-through and thermal conduction when positioned in close proximity to the
hot work site in a horizontal or vertical orientation and exposed to sparks, flames, and heat. Blankets may
not resist molten metal burn-through.
3. Welding curtains are intended for use where the hot work exposure is mild. FM Approved welding
curtains are designed to resist burn-through or deformation when oriented vertically and positioned distant
from sparks and flames.
4. Ensure seams between multiple pads, blankets, and/or curtains overlap sufficiently and openings at
the bottoms of curtains are covered to prevent hot work ignition sources from escaping.
2.5.2.2.3 Remove combustible accumulations (debris, dust/lint, or residues) and pooling ignitable liquid (due
to spills or leaks) from the hot work area. Thoroughly inspect the hot work area for accumulations in spaces
hidden from sight such as in trenches or pits, underneath equipment, within partially-enclosed equipment,
and atop cable trays, ductwork, or suspended ceilings. Perform the appropriate housekeeping activities to
remove combustible accumulations and pooling ignitable liquid. Do not use wet-down as an alternative to
removing combustible accumulations.
2.5.2.2.4 Isolate potential sources of flammable gas, ignitable liquid, and/or combustible dust/lint that may
be released into the hot work area during work. Conduct a job safety analysis to identify sources of these
materials, and to determine the appropriate isolation method. Typically, isolation starts with a minimum of
de-energizing the equipment, but may also include blocking, draining, and purging equipment. Consider the
following when isolating sources of flammable gas, ignitable liquid, and/or combustible dust/lint:
A. When a more-reliable blocking method is warranted, consider a double-block and vent valve
arrangement, or physically disconnecting material sources by temporarily installing a pipe blank, cap, or
plug.
B. When a less-reliable blocking method is used due to a lack of available options (e.g., a single-block
valve), consider performing frequent checks or constant atmosphere monitoring to verify adequate isolation
as discussed in Section 2.5.2.2.5.
C. When draining and purging is warranted, ensure all low-points are identified and verified clear prior
to work.
D. Use safety programs such as lock-out tag-out, confined space entry, and line-breaking.
2.5.2.2.5 Test the hot work area for flammable vapor/gas prior to work and as-needed during work. When
conducting atmosphere monitoring, immediately stop work if the atmosphere exceeds 1% of the lower
explosive limit (LEL).
2.5.2.2.6 Protect or shut down ventilation and conveying systems in the hot work area. These systems may
contain combustible material or transport hot work ignition sources outside the hot work area to downstream
combustible accumulations or filters. If ventilation is needed for an enclosed hot work site, provide the
following safeguards:
A. Use a temporary ventilation system constructed of noncombustible components and remove air filters.
If particulate filtration is needed, use an FM Approved Class 1 air filter.
B. If negative ventilation is used, extend the hot work area to include the area around the fan discharge.
C. If positive ventilation is used, ensure the airflow does not disperse hot work ignition sources outside
the hot work area as discussed in section 2.5.2.2.1 or compromise the arrangement of hot work blankets
and curtains as discussed in section 2.5.2.2.2.
2.5.2.2.7 If one of the following conditions exists, extend the hot work area to include the opposite side of
a building assembly (i.e., floor, wall, ceiling, or roof):
A. The building assembly has an opening within the hot work area as shown in Figures 4 and 5. Openings
may allow hot work ignition sources to pass through, exposing combustible material on the opposite side
of the assembly. Examples of openings include: penetrations for cables, piping, conveyors, or ventilation
ductwork; stairways; or equipment or personnel doors. Refer to Section 2.5.2.2.1 when defining the hot
work area on elevated mezzanines or open process structures.
B. The hot work site is on or near thermally-conductive materials passing through the building assembly.
Thermal conduction may ignite combustible material on the opposite side of the assembly. Examples of
thermally-conductive materials include metal piping or steel structural members.
2.5.2.2.8 Identify and safeguard any combustible-lined equipment, piping, and/or ducts in the hot work area
when the equipment has openings that could allow hot work ignition sources to enter. Refer to Section
2.5.2.2.2 for recommendations on covering openings, or Section 2.5.2.3.6 for recommendations on protecting
combustible-lined equipment.
Hot work R
site
Hot work
Opening in area
roof
Hot work
area
R = 35 ft. (10 m)
H = 15 ft. (5 m)
Fig. 4. Rooftop hot work permit-required area
R
Hot
work
site
Opening
Hot R+
work area R = 35 ft. (10 m)
R+ = 35-50 ft. (10-15 m)
Hot H = 15 ft. (5 m)
work
area
2.5.2.2.9 Treat hot work on thermally-conductive materials at or near penetrations into combustible building
assemblies as a hot work high-risk operation. In addition, take the following additional required precautions:
A. Remove portions of the building assembly around the penetration and use suitable noncombustible
replacements.
B. Monitor the temperature of the thermally-conductive material before the penetration.
C. Temporarily install a thermal sink on the thermally-conductive material before the penetration.
D. Perform fire watches using an infrared camera to inspect for hot spots. Stop work immediately and
initiate emergency action if hot spots are detected.
E. Report all “hot spots” or fires, even if extinguished to the fire service. Smoldering may continue after
extinguishment and may take place for hours before flaming begins in areas unsuspected by non-
professionals.
2.5.2.2.10 Treat hot work on combustible building assemblies as a hot work high-risk operation. Examples
of such hot work may include cutting through a non-FM Approved (Class 2) insulated steel deck roof or
insulated metal panel, or welding seams of insulated metal panels. When performing these operations, follow
the guidelines of the building system manufacturer, and take the following additional required precautions:
A. Develop a fire emergency response plan that includes conditions under which the fire service should
be notified, and verify the fire service has access to the work area.
B. Stop work immediately if material appears to be smoking.
C. Perform fire watches using an infrared camera to inspect for hot spots. Stop work immediately and
initiate emergency action if hot spots are detected.
D. Report all “hot spots” or fires, even if extinguished to the fire service. Smoldering may continue after
extinguishment and may take place for hours before flaming begins in areas unsuspected by non-
professionals.
2.5.2.2.11 Treat work on torch-applied roofing systems as a hot work high-risk operation. Work may include
installing, altering, or repairing roof systems. Torch-applied roofing includes modified bitumen roof covers
using an open-flame roofer’s torch. When using torch-applied roofing systems, follow the guidelines of the
roofing system manufacturer, and take the following additional required precautions:
A. Follow guidelines within FM Global Data Sheet 1-33, Safeguarding Torch-Applied Roof Installations.
B. Develop a roof-fire emergency response plan that includes conditions under which the fire service
should be notified, and verify the fire service has access to the work area.
C. Stop work immediately if roofing materials appear to be smoking.
D. Conduct a continuous fire watch over the hot work area during torch application.
E. Conduct the post work fire-watch in accordance with Note 1 of Table 1, and adhere to the following:
1. Where thermal imaging such as an infrared camera is used to check all roof areas worked on for
hot spots, if temperatures are in excess of 250 °F (121 °C), remove and safely discard all charred or
smoldering insulation and roof covering, including materials within a 4 ft (1.2 m) radius beyond. Initiate
emergency action if hot spots are detected.
2. Inspect the entire top surface of the roof area worked on as well as the inside of the building for
signs of fire, dripping bitumen or smoke. Pay particular attention to areas around roof expansion joints
and other roof penetrations.
F. Conduct fire monitoring in accordance with Note 1 of Table 1 and 2.5.4.2.
G. Report all “hot spots” or fires, even if extinguished to the fire service. Smoldering may continue after
extinguishment and may take place for hours before flaming begins in areas unsuspected by non-
professionals.
H. When using an asphalt kettle: Locate the kettle a minimum of 25 ft (7.5 m) from the building and
combustible yard storage, ensure the kettle is attended at all times while in operation, and provide an
appropriate fire extinguisher nearby.
A. The hot work area and person performing the hot work are not visible from a single vantage point.
B. The hot work area is large, multi-level, and/or congested.
C. The hot work area extends to the other side of a building assembly due to an opening or thermally-
conductive penetration.
2.5.3.3 Restrict the scope of a hot work permit to that defined on the authorized permit. Ensure the type of
hot work operations and the location of hot work sites do not change once the permit is authorized. Changes
may require redefining the hot work area and modifying the required precautions. If conditions do change, stop
work and reauthorize the permit before continuing.
1, 2
Table 1. Construction and Occupancy Factors for Determining Post-Work Fire Watch and Fire Monitoring Periods
Construction Factors
Noncombustible Combustible Combustible
construction or FM construction without construction with
Approved Class 1 or concealed cavities 3 unprotected concealed
Class A building cavities 4
materials
Watch Monitor Watch Monitor Watch Monitor
Noncombustible with any combustibles 30 min. 0 hours 1 hour 3 hours 1 hour 5 hours
Occupancy Factors
2.6.6 Provide fire extinguishers within the low-energy hot work area per local codes. Inspect, test, and
maintain fire extinguishers per Data Sheet 2-81, Fire Protection System Inspection, Testing, and Maintenance.
2.6.7 Conduct inspections of low-energy hot work areas to ensure required precautions are maintained.
Inspect work areas at least weekly.
12000ºF 6000ºC
Electric arc
Electric arc
10000ºF
8000ºF 4000ºC
2000ºF
Fig. 6. Hot work ignition source temperature vs. solid-fuel ignition temperature
A policy statement should set the ground rules for conducting hot work both inside and outside buildings.
Alternative cold work methods and relocating the work to a hot work designated area should always be
considered first. If hot work is unavoidable, the policy should define the location of hot work designated areas
and hot work production areas. One of the most important aspects of the policy is to define the rules for
hot work permit-required areas (including procedures to be used) and identify hot work high-risk areas.
Procedures and training should supplement the policy statement with more details on inspection of hot work
designated areas and hot work production areas, and rules for permit-required hot work including preparing
the hot work area, permit authorization, and permit expiration. Preparing the hot work area and/or equipment
is arguably the most critical aspect of performing hot work that requires a permit. All hot work fires and
explosion can be prevented by controlling combustible, ignitable, and flammable materials. A hot work fire
or explosion will not occur unless hot work ignition sources come into contact with these materials. However,
in practice, controlling fuel and ignition sources can be difficult, and methods of doing so can, at times, be
unreliable. As a result, a second layer of protection should be provided during permit-required hot work to
mitigate the consequences of a hot work fire. Examples include ensuring fire protection systems are in
service, and supervising the hot work area during and after the work to check for fire-safe conditions.
During a night shift, contractors were installing a new gas supply line to a furnace. The gas piping was
assembled using welded joints and run at ceiling-level. While working, the welder noticed a small fire involving
dust accumulations below the hot work site on a steel beam flange. The welder attempted to extinguish the
fire using his foot, then a fire extinguisher. The fire extinguisher dispersed the dust and fire spread to a cable
tray below that also contained dust deposits. The fire spread on the horizontal cable tray, then vertically to a
main cable rack containing cables feeding the entire cast house. The fire was extinguished by facility
personnel after isolating power and using fire extinguishers.
The cast house was not a hot work permit-required area. Instead of a hot work permit, a work permit was
used that identified a fire risk requiring a fire watch. Regardless of the permit used, the facility failed to properly
remove or protect combustibles in the hot work area.
3.2.1.1.4 Fire at a Metal-Working Facility Involving a Belt Conveyor and Combustible Residue
A facility manufactured rotors and stators for electric motors. The production building was steel-frame
construction with steel purlins supporting insulated metal panels. Walls were cinderblock. The cast house
consisted of noncombustible construction. Automatic sprinkler protection was provided in the fire area.
During a night shift, employees were torch-cutting in the vicinity of a press at floor level. Sparks fell into a
conveyor pit beneath the row of 10 mechanical presses, igniting oil residue and the wide rubber conveyor used
to collect scrap metal from the presses. Sprinkler protection in the conveyor pit was impaired and the fire
spread throughout the tunnel, damaging all presses. The fire was eventually extinguished after consuming
most of the available fuel.
A hot work permit was not used. Workers failed to recognize the combustible materials in the pit underneath
the hot work site or verify that fire protection was in service.
3.2.1.1.5 Fire at a Food-Processing Facility Involving Combustible Wall Construction
A meat processing and packing plant had interior insulated metal panel walls. Automatic sprinkler protection
was provided throughout the building of fire origin.
A contractor was cutting and welding a metal sleeve penetration through a thick insulated metal panel wall
assembly (multiple wall panels plus additional insulation) in preparation for installing an exhaust duct. The
work ignited the insulation and the fire spread upward and through the insulated wall cavity.
A hot work permit was not used. Workers failed to recognize the combustible wall construction.
3.2.1.1.6 Fire at a Sawmill Involving Combustible Debris with Impaired Fire Protection
A sawmill produced kiln-dried dimensional lumber. It had a mostly combustible roof and combustible cavity
walls. Automatic sprinkler protection was provided throughout the building of fire origin.
During a weekend maintenance shutdown, a contractor was cutting on production equipment. In preparation
for the work, a hot work permit was completed and authorized and the hot work area was wet down with
a process water line on both the production floor and open areas below. Shortly after beginning work, the
fire watch discovered a smoldering fire beneath the hot work site. When attacked with the wet-down hose,
the fire flared and begin spreading. Mill personnel responded with wet-down houses and fire hoses, and
notified the fire service. Several minutes into the fire, a closed sprinkler control valve was opened. Over the
next few hours, a combination of sprinklers and firefighting efforts controlled the fire. Eighteen hours after the
fire began it was officially extinguished. The building suffered significant damage due to the smoldering fires
in combustible concealed spaces, and the fire service having opened building wall, ceiling, and roof cavities.
A hot work permit was used; however, the permit authorizer was unaware sprinkler protection in the hot work
area was impaired because impairment management procedures were not followed. Combustible
accumulations and residue were not removed (wet down) and non-moveable combustible materials
(combustible construction and cables) were not covered.
3.2.1.1.7 Fire at a Steel Pickling Plant in a Boiler Room Involving Combustible Wall Construction
The facility pickled, slit, and stamped hot rolled steel coils. The plant was mostly noncombustible construction
with steel frame supporting standing seam metal panels. The interior steel surfaces were coated, shielded
with fiberglass reinforced plastic panels, or insulated with expanded foam to limit acid corrosion. Automatic
sprinklers were not provided within the building.
Employees were cutting steel equipment supports in the boiler room when exposed foam insulation was
ignited. The workers left the room to alert building personnel. The fire quickly spread along combustible wall
and ceiling surfaces. Several hours after ignition, having consumed most of the available combustible loading
in the area, the fire was extinguished by the fire service.
A hot work permit was used, but information was not available on most of the precautions implemented. A
during-work fire watch was not in place. The workers failed to recognize the exposed foam insulation.
3.2.1.1.8 Fire at a Sawmill Involving Combustible Debris with Impaired Fire Protection
The facility was a sawmill that produced dimensional kiln-dried lumber. The subject mill building consisted
of either steel or wood frame supporting a combustible roof, while walls were mostly wood on wood frame.
Automatic sprinkler protection was provided throughout.
Employees were torch-cutting sprinkler piping on the sawmill operating floor. The workers broke for lunch.
Later on, other personnel returning from work noticed a glow on the floor below the operating floor. Personnel
attacked the fire with a fire hose and later the sprinkler control valve was opened (system was under repair).
Five hours later the fire was extinguished by the fire service after controlling spread and limiting the fire to
the building of origin.
A hot work permit was used, but information was not available on most of the precautions implemented.
The workers failed to recognize floor openings and remove combustible accumulations from the floor below.
A continuous during-work fire watch was not in place during the lunch break. Sprinkler protection was
impaired during the work.
While operating, repairs were made to an elevator down-spout that had a worn-through plastic liner and metal
casing. Approximately 30 to 60 minutes after the work had been completed fires were detected in all elevators
and interconnected plastic-lined equipment and belt conveyors. The fire service responded and was able
to control the fires within one hour.
No hot work permit was used. The facility failed to recognize that plastic-lined equipment is a hot work
prohibited area.
3.2.1.2.7 Fire at a Power-Generating Facility Involving Combustible-Lined Equipment
The facility was a coal-fired power generating station. The facility used absorbers that were used to scrub
sulfur containing combustion products in the flue gas. The absorbers were tall concrete structures with plastic
slurry distribution trays and other plastic components.
During a maintenance shutdown, repairs were made to cracks in the stainless steel ductwork leaving the
absorber. The hot work site was located above and in close proximity to the plastic mist eliminators and
distribution trays. After the work was completed, personnel noticed smoke emanating from the absorber
exhaust stack. The emergency response team was unsuccessful at putting water into the absorber, so slurry
pumps were turned on to circulate aqueous solution through the unit. The fire was eventually controlled about
90 minutes after detection.
No hot work permit was used. The facility failed to recognize there were combustible parts within the mostly
noncombustible equipment. This was the second absorber fire in about 10 years caused by hot work at this
facility.
3.2.1.2.8 Fire at a Mining and Ore Processing Facility Involving Combustible-Lined Equipment
The facility was a diamond mine and processing facility. The front-end of the processing facility utilized
combustible equipment and rubber-lined equipment.
During a maintenance shutdown, employees were torch-cutting and performing cold-work on rubber-lined
equipment. When workers broke for lunch a fire started and spread through equipment. It was eventually
extinguished an hour later by the fire service.
A hot work permit was used. The facility failed to recognize combustible-lined equipment, and a continuous
during-work fire watch was not employed.
4.0 REFERENCES
4.1 FM Global
Data Sheet 2-81, Fire Protection System Inspection, Testing, and Maintenance
Data Sheet 3-26, Fire Protection Water Demand for Nonstorage Speinklered Properties
Data Sheet 7-59, Inerting and Purging of Tanks, Process Vessels and Equipment
Data Sheet 7-78, Industrial Exhaust Systems
Data Sheet 10-4, Contractor Managementmed
Hot Work Permit System Kit with permit holster and permits (P9311k)
Hot Work Permit (F2630)
Don’t Get Burned By Hot Work (P9802)
Pocket Guide to Hot Work Loss Prevention (P9602)
Understanding the Hazard: Hot Work (P0032)
Understanding the Hazard: Contractor Management (P0110)
Managing Hot Work Online Training Flyer (P0686a)
Advancing Hot Work Skills Online Training Flyer (P12062)
Managing Hot Work Online Training Flyer (P08109e)
4.2 Other
Australian Standard (AS) Safety in Welding and Allied Processes, Part 1: Fire Precautions. AS 1674.1.
Fire Protection Association (FPA). Recommendations for Hot Work. RC-7.
National Fire Protection Association (NFPA), Standard for Fire Prevention During Welding, Cutting, and Other
Hot Work. NFPA 51B.
VdS Schadenverhuetung GmbH. Fire Protection Guidelines, ″Safety Guidelines for Hot Work″ Number VdS
2008:2009-07
Welding curtain, FM Approved: A heat-resistant fabric designed to be placed in the vicinity of a hot work
operation. The curtain is intended for vertical orientation while subjected to light to moderate thermal
exposures from hot work activities such as grinding, mechanical cutting, and welding that does not result in
molten metal contact (i.e., no slag exposure). The curtain is intended to prevent sparks from escaping a
confined hot work area. A curtain provides the least thermal protection compared to a blanket or pad.
Welding pad, FM Approved: A heat-resistant fabric designed to be placed directly beneath a hot work
operation. The pad is intended for horizontal orientation while subjected to moderate to severe thermal
exposures from hot work activities such as torch cutting and welding that may result in molten metal contact
(i.e., slag exposure). The pad is capable of resisting burn-through and thermal conduction through the pad
that may ignite combustibles on the opposite side of the pad. A pad provides the most thermal protection
compared to a blanket or curtain.
September 2001. This data sheet has been completely rewritten and supersedes the preceding Data Sheet
9-5/15-1, Hot Work.
The following areas of the facility are defined as hot work designated, hot work production, hot work
permit-required, and hot work high-risk.
[List or Insert floor or site plan showing the areas.]
Hot Work Permitting (Minimum Requirements)
1. All hot work permits will be reviewed and authorized by the designated permit authorizer.
2. All contractors will be required to use the facility’s hot work permits, including facility authorization (by the
designated permit authorizer) and supervision.
3. All facility and contractor personnel conducting hot work, performing fire watch, or fire monitoring will be
trained on the hot work permit system at least annually. Permit authorizers will also be trained at least annually.
4. A management audit of the program, including a review of program records and facility changes, will be
conducted at least annually.
5. An incident log of all hot work fires will be maintained, in which deficiencies and corrective actions will
be identified.
6. Permit-required hot work will be provided with post-work fire watches and fire monitoring periods as shown
below.
[Insert list or floor/site plan showing the post-work categorized areas.]
Additional Resources
1.Refer to the following internal procedures for additional requirements and guidance on the hot work
management program:
• [List SOPs]
2.Refer to the following external resources for additional hot work management guidance:
• [www.fmglobal.com and/or other websites]
Program Owner: Signature:
Manager Endorsing Program: Signature:
Effective Date of Policy: