Dont Get Burned

by Hot Work

reventing fire caused by hot work takes teamwork between management

and facility personnel. Executive-level managers need to be involved
to enforce a solid program of property loss prevention and monitor
workers closely. And, facility personnel need to play their part by following
all precautions, no matter how insignificant they may seem.
This brochure defines the key elements of a successful hot work management program. It outlines for executives how to develop and implement an
effective hot work policy. And, it details for facility personnel, as well as
outside contractors, guidelines for safely performing hot work operations.

This brochure is made available for informational purposes only in support of the insurance relationship between FM Global and its clients.
This information does not change or supplement policy terms or conditions. The liability of FM Global is limited to that contained in its insurance policies.

No Industry Is Safe
Hot workany operation that
produces flames, sparks or heat
is an established cause of fire and
explosions throughout the world.
FM Global loss history shows there
is no industry or type of facility
immune to his hazard. Cutting, welding, brazing, grinding, sawing, sweat
soldering, applying roof covering,
sealing plastic shrink-wrap by torch,
and using a plumbers torch are all
examples of hot work.
According to FM Global records, during the past five years, hot work was
the second most costly cause of ignition of fire or explosion. In fact,
a summary of FM Global hot work
fires from 2003 to 2012 (a ten-year
period), shows there have been 282
losses with an indexed gross of
US$946.8 million in property loss and
interrupted operationsan average
of US$3.4 million per fire. Of those
losses, all could have been prevented
with proper hot work management.
Small and large companies that utilize
the FM Global Hot Work Permits say
that their success in preventing fires
caused by hot work is not possible
without top managements support of
a strong hot work program.

Management: Create and

Audit the Policy
Causes of Hot Work Fire
Each year, the same management
oversights prevail:
n 
Incomplete property loss
prevention procedures
n 
Personnel not following
managements guidelines for
protecting property
n 
Untrained personnel or unsupervised contractors taking shortcuts
in the procedures
n 
Weak or out-of-date policies
inspiring complacent supervision
at the work sites
Implementing a Hot Work
Management Program
n 
Control personnel activities
before, during and after each
hot work job.
n 
Put your hot work policy in
writing and distribute it to all
personnel (including contractors)
involved with any part of the
hot work process.
n 
Review and update the policy
at least annually, otherwise
changes in personnel or downsizing could keep the program from
remaining effective.
n 
Train all personnel in how to
follow hot work precautions.

Loss studies show many companies

experiencing a hot work loss neglected
four steps. Make sure your management program emphasizes them:
1. Seek another method. Search
for an equally effective way to
join, trim or sever without compromising mechanical integrity.
2. Prepare the area properly.
Follow the hot work 35-foot
(11-meter) rule on page 6 and
emphasize these precautions:
n 
Make sure construction in the
work area is noncombustible,
including insulation.
n 
Remove combustible contents,
or cover with FM Approved
blankets or pads.
n 
Sweep floors clean; wet down
combustible floors. Cover
them with wet sand or fireresistive sheets.

Remove ignitable liquid, dust,

lint and oily deposits; purge
ignitable liquid and flammable
vapor from containers.
n 
Monitor the hot work area for
at least four hours after the job
is finished. Throughout the first
hour, the fire watch continuously monitors the work site and
adjacent areas. The areas should
then be checked throughout the
next three hours by appropriate
electronic surveillance or another
suitable option, such as a trained
alternate for the fire watch or
a security guard.
3. Make sure both fire protection
and hot work equipment work
properly. Make sure the sprinkler system water supply control
valves are open and operable. If
there is a fire pump on-site, check
n

to see that its operation is on automatic. Fire hose and extinguishers need to
be available, be in service and operate
properly. Hot work equipment should
be in good condition.
4. Train the fire watch:
n 
Make sure the fire watch checks
adjoining areas, including above
and below the work area, and
watches for fire during the hot
work operation. This is especially
critical where openings exist.
n 
Train the fire watch in using fire
protection (extinguishers and
charged hose lines) and sounding
the fire alarm.
How Effective Is Your Hot Work
Management Program?
n 
Do you have a written management policy covering plant or
corporate intention to control hot
work? Is it clearly communicated
to all employees and contractors?

Top Ignition Sources of Fire and Explosion (2000 through 2004)

(Gross Loss in Percentages)
Every year, hot work is among the top five causes of increasingly
severe and frequent fire and explosion FM Global insured properties.
While employees performing the hot work accounted for 59 percent
of the gross loss amount, contractors accounted for 71 percent of the
total number of fires/explosions.
Electrical
Hot work
Spontaneous ignition/chemical action
Hot surfaces/radiant heat
O
 thers, including arson/incendiarism,
friction, exposure, spark, open flames
(other than hot work) and overhearting.
4

24%
19%
11%
10 %
36 %

24%
19%
36%
11%
10%

 Do you clearly communicate detailed, written hot work property

loss prevention procedures to all
employees and contractors?
n 
Do the procedures include all of
the following:
A requirement to seek
alternative methods to
hot work, particularly
during the design phase of
all new construction, repair
and maintenance projects?
A process for evaluating the
need for hot work?
An assigned, named position
to manage the hot work
program?
An assigned, trained, authorized hot work supervisor?
Employee education and
empowerment to stop unsafe
hot work operations?
Control and education of
contractors?
Formally stated consequences
for violating procedures?
n
Are fire-safety supervisors:
Knowledgeable in fire hazards pertaining to building
contents, operations and facility construction?

Fully trained in hot work
property loss prevention
supervision?
Available (or on call)
24 hours a day?
Contacted for all hot work
(inside and outside of
facility buildings)?
Authorized to stop all
hot work?

Required to visit all sites
before approving hot work?
Required to personally complete the Hot Work Permit?
(This tag is conspicuously
posted at the job site by the
fire-safety supervisor.)
n

Managing Outside Contractors

The trend toward outsourcing
maintenance and renovations has
its risks. A contractor may have the
technical expertise to perform hot
work, but he or she is not likely to
have a full understanding of property
loss prevention.
Before allowing contractors to
start any job, its crucial you make
sure they:
n 
Sign a contract agreeing to faithfully follow your hot work policy
and understand the job will not
proceed without one; and
n 
Demonstrate proficiency in your
companys hot work safety training program and ability to carry
out procedures.
It also is essential to:
Make it clear to all contractors
(and facility personnel) your policies and regulations are to be followed or they will face potential
job termination.
n 
Obtain references from other
customers of any contractors you
might be considering.
n 
Make sure bids and contracts
clearly state your hot work policy.
A few days before hot work begins, inform contractors in writing
they are responsible for following
your policy.
n 
Discuss the planned work with
each contractor. Inquire about the
contractors expertise and concern
for the possible hazards, especially as they relate to the building
and work environment where the
hot work will be conducted.
n 
Confirm contractors have
proper insurance.
n 
Avoid signing any hold-harmless
clause created by any contractor.
n 
Avoid waiving your companys
subrogation rights.
n

Empowering Personnel and

Making Them Accountable
Combustible products ignite from hot
work just about anywherein offices,
storage, manufacturing, even resorts.
As a result, its crucial that facility
personnel play their part in controlling
hot work operations by following
every precaution, no matter how insignificant it might seem. Cutting just one
corner undermines the whole hot work
management effort and creates opportunity for another near miss or major
loss. And, property loss can amount to
job loss. (For more information on the
role of facility personnel, see page 7.)
The Importance of Fire Protection
Manual fire protection (extinguishers,
hose, etc.) should be operating and in
place before the job starts. If automatic sprinkler protection is provided
for the area, make sure the system is in
service. The presence of sprinkler protection means either the area contains
or is constructed of combustible material. And that one wordcombustibleis a critical reason for conducting
hot work with great care.
Other FM Global Hot Work
Resources
Be sure to take advantage of other
FM Global resources that provide
more complete information on
controlling hot work:
n
Hot Work Permit form (F2630)*
n 
Hot Work Permit System Wall
Hanger (P9311)*
n 
Pocket Guide to Hot Work
Loss Prevention (P9602)*
*Available in several languages.

The Hot Work 35-Foot (11-Meter) Rule

Its critical that any area within 35 feet (11 meters) of
the hot work is kept clear of combustible material:
n 
Shield combustible flooring with wet sand,
fire-retardant tarpaulins or sheet metal.
n 
Clean up the area, especially of oily
deposits and trash.
n 
Cover any storage or other combustible
material that cannot be moved out
with FM Approved blankets or pads.
Block off any duct openings.
Ductwork provides an easy path
for sparks to travel to other areas of
the facility or to ignite deposits or
linings within the ductwork.
n 
Cover or fill any openings in exposed
walls, the floor and the ceiling with
noncombustible material or
FM Approved fire-stop material.
n 
Relocate any combustible material on
the other sides of the walls being worked
on. Clean dust and deposits outside and inside
enclosures and ducts.
n 
If hot work will occur at an elevated location (e.g., on
building framing, the ceiling or underside of the roof),
provide a fire-retardant covering under the work area.
n 
Close all doors and fire doors. First, check to be sure
there is no significant gap under the door or along its
sides. Sparks can roll under a closed door and ignite
combustible material outside the hot work area.
n 
Shut down ducts and conveyor belts, which can carry
sparks to distant combustible material.
An alternative to the 35-foot (11-meter) rule is to designate
an area only for hot work. This assumes the item being
worked on can be moved into this area. Isolate the area
from the rest of the facility using noncombustible screens
or partitions. And, never let it become a temporary
storage area.

Above:
It is critical that any area within
35 ft. (11m) of the hot work is kept
clear of combustible material.

Facility Personnel: Know the Hazards, Follow the Policy

The Hazard
The hot work hazard is often hidden,
even to the most experienced workers.
For example:
n 
Almost everything surrounding
you can burn. Sparks and molten
globules become uncontrolled
ignition sources, often flying or
rolling long distances. One spark
landing on or near combustible
materiallike insulation, wood
particles or ignitable liquidis
enough to start a fire.
n 
Sparks can settle in areas you
cant see, such as the tops of high
ledges, floor openings, vents or
recessed walls or ceiling openings. And, they can smolder unnoticed for hours before igniting
a blaze.
n 
Combustible material is not
always visible. Cutting into a
metal wall can ignite the inside
wall. With enough heat, anything
combustible on the other sideor
close to itcan catch fire.
n 
The flame of a hot torch can
reach up to 6,000F (3,316C).
Hot work on vessels or tanks can
ignite fire and explosion fueled
by flammable deposits, vapor or
gas that often are invisible unless
the vessels or tanks are properly
inerted and checked beforehand.
n 
Poorly maintained hot work
equipment, such as hose and
connections leaking gas, can
ignite fire.

As a result, its important that facility

personnel play their part in minimizing the risk of loss created by the hot
work hazard. Although the fire-safety
supervisor and fire watch are responsible for specific duties, as outlined
below, all employees need to assume
accountability for following the
precautions outlined in your hot
work policy.

The Fire-Safety Supervisor

The fire-safety supervisors duties
include enforcing the companys
hot work policy and managing the
activities of the fire watch and all
outside contractors. Before authorizing any hot work job, he or she must
ask two questions:
1. Is hot work the only option?
Explore all other options first.
Can work be completed some
other way? Often the answer is
yes. Consider:

n 
Cutting with a hand or electric saw, or pipe cutter

n 
Using a mechanical way
to join items together with
nuts and bolts, screwed fittings or couplings

n 
Using hand-filing instead
of grinding

n 
Installing threaded pipe
instead of welded or soldered
where local codes permit

n 
Avoiding torches (many
types of FM Approved roof
coverings can be installed
without torches)

Facility Personnel: Know the Hazards, Follow the Policy (continued)

2. Can hot work be performed
in the area?

n 
Visit the proposed hot work
site, even if youre familiar
with it.

n 
Tour surrounding and adjacent areas (adjoining rooms
and areas on the floor above
and below).

n 
Forbid hot work on equipment with combustible lining.

n 
Avoid hot work on metal piping and ducts passing through
combustible construction if
high temperatures could
affect that construction.

n 
Prohibit hot work in any area
where the hazard cannot be
eliminated or controlled,
and clearly post NO HOT
WORK signs or equivalent. Examples of such areas
include:
Any hazardous process
involving ignitable liquid,
gas and dust that cannot
be shut off
Concentrations of flammable vapor, gas or dust
that cannot be eliminated
Walls, ceilings or floors
that have combustible
facings or combustible
insulation
Combustible storage that
cannot be relocated or
covered completely with
a fire-retardant cover

Authorizing the Hot Work Job

If there is no alternative to hot work,
and the area in question is fire-safe,
the fire-safety supervisor uses the
three-part FM Global Hot Work Permit to authorize the hot work. Before

signing the permit, he or she discusses

with the hot work operator and the fire
watch exactly what the work will
involve, and ensures precautions on
the permit have been taken. Then, one
part of the permit is displayed prominently in the work area, while the
others remain with the supervisor
one for quality assurance and the
other for filing. Precautions listed
on the permit include:
1. Identify what combustible
material and types of ignitable
liquid are in the immediate and
surrounding area. Then:

n 
Shut off, drain and purge ignitable liquid piping systems.

n 
Relocate ignitable liquid and
combustible material at least
35 feet (11 meters) away from
the work area.

n 
Remove lint or dust deposits.

n 
Clean up scrap material
from the floor and nearby
equipment.

n 
Look for concealed spaces
and openings into adjacent
areas, and spaces below,
adjacent or above the work
area. Seal openings (basements, the floor above the
work area, spaces above
the ceiling, ductwork, hollow
walls, etc.) tightly with noncombustible or fire-retardant
material.

n 
Use FM Approved welding
pads, blankets and curtains to
fully shield items that cannot
be moved due to their size,
including combustible walls,
ceilings and floors.

n 
Plug floor, ceiling and wall
openings with an appropriate
fire-stop material.

2. Verify existing automatic fire protection systems remain in service

and appoint only trained personnel to use the portable equipment.

n 
Bring portable fire extinguishers to immediate and surrounding areas.

n 
Lay out and charge fire hose.

n 
If automatic sprinklers are
not installed in the area of hot
work operations, alert the local fire service that hot work
is being performed.

n 
Advise the plant emergency
response team and security
personnel about the hot work
activity, including its location
and involved personnel.

Facility Personnel: Know the Hazards, Follow the Policy (continued)

G
WARNSSIN! Watch for fire!

ORK IN

HOT W

3. Assign a qualified fire watch to

monitor the hot work area and
other areas exposed to stray
sparks or heat, including areas
not directly visible from the
immediate hot work area.
4. Make sure only qualified employees or contractors perform the hot
work; review their credentials for
the job.
5. Verify all hot work equipment
is in good working condition,
especially hose attachments. This
includes contractor equipment.
6. Make sure all personnel involved
with the hot work job know
when and how to summon
emergency assistance, should it
be needed (location of phones,
numbers, etc.).
7. Assign personnel to adjacent
areas, including the floor above
and below, to watch for possible
fire during the hot work operation.
This is especially critical when
openings exist.
8. Issue the Hot Work Permit to expire at the end of the shift or after
eight hours, whichever is shorter.
9. After investigating the hot work
site and verifying all items listed
above, complete the Hot Work
Permit, including:

n 
Name of person (employee or
contractor) performing the job

n
Date of job and job number

n
Location of hot work

n
Nature of job

n
Date and time of expiration

10. Ensure the person performing

the hot work hangs the completed permit in a visible place
in the work area.
11. Reinspect the hot work area
and surrounding space at the
end of the monitoring period.
If all is safe, sign the permit,
remove it from the area, and
keep it for a record.

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Fire

The Fire Watch

The fire watch reports to the fire-safety
supervisor. The job of the fire watch is
twofold: Prevent fire and be ready to
respond if one starts. Specifically, the
fire watch:
n 
Stays near the person performing
hot work
n
Closes all fire doors
n 
Makes sure the work area remains
free of combustible material and
tarpaulins are not moved
n 
Monitors the hot work area for at
least four hours after the job is finished. Throughout the first hour,
he or she continuously monitors
the work site and adjacent areas.
During the next three hours, the
areas should be checked by appropriate electronic surveillance or
another suitable option, such as a
trained alternate for the fire watch
or a security guard
n 
Pays particular attention to hot
work jobs at elevated locations,
on the building roof, or in walls,
and inside buildings with multiple
floors; these areas often are not

watched carefully enough and

frequently have ignited from
stray sparks smoldering long after
workers have left the job site
n 
Never leaves the area while
work is in progress or during
breaks (such as coffee or
lunch) unless relieved by a
qualified replacement
n 
Stops the hot work if improper
conditions develop
n 
Is ready to sound the alarm and
use an extinguisher or fire hose if
a fire starts

Follow All Hot Work

Permit Precautions
FM Globals Hot Work Permit has
long been reliable for helping companies prevent fire caused by hot work,
but it is just a tool, effective only if it
is followed carefully. Used properly, a
permit tracks each step of a hot work
job, and serves as a guide, a warning
tag and careful record.

Contact Us:

Product Ordering Information:

To report an impairment or to find an FM Global office

nearest you, visit www.fmglobal.com/contact.

For additional copies of this publication or other

FM Global resources, order online 24 hours a day,
seven days a week at www.fmglobalcatalog.com.

Report A Loss:
P9802 2013 FM Global
(Rev. 03/2013) All rights reserved.
www.fmglobal.com
In the United Kingdom:
FM Insurance Company Limited
1 Windsor Dials, Windsor, Berkshire, SL4 1RS
Regulated by the Financial Services Authority.

Dial (1)877 NEW LOSS (639 5677)* to report a property

or cargo loss 24 hours a day, seven days a week.
Or, to contact your client service team or designated
claims office directly, go to www.fmglobal.com/claims
or www.affiliatedfm.com/claims for location and
contact information.
*For clients of FM Global and Affiliated FM
in Canada and the United States only.

Or, for personal assistance worldwide, contact our

U.S.-based customer services team, Monday Friday,
8 a.m. 5 p.m. ET:
n
Toll-free: (1)877 364 6726
(Canada and the United States)
n Phone: +1 (1)401 477 7744
n Fax: +1 (1)401 477 7010
n
E-mail: customerservices@fmglobal.com