Loss Prevention Advice

The ongoing risks associated with hot work, such as welding and grinding, which continue to cause serious fires at ports, terminals and warehouses.

Hot work refers to any activity that generates flames, heat or sparks, including welding, cutting, grinding and soldering. These operations pose a significant fire or explosion risk, particularly in confined spaces or near flammable cargo, equipment or infrastructure. When hot work is not properly controlled, the resulting fires can have tragic consequences, endangering lives, disrupting operations and causing environmental damage.

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One which killed more than 200 people. While the exact cause remains under investigation, early reports have suggested the explosion may have been triggered by a fire originating from welding work.

In December 2025, the International Association of Classification Societies (IACS) published revisions to its welding rules for marine and offshore structures, to better align with international welding standards, improve qualification standards and ensure consistency. 

Essential controls

• All hot works should be carried out under a formal hot works permit.
• The permit should, as a minimum, specify:
1. the location of the work;
2. the person(s) carrying out the work;
3. a description of the work;
4. the proposed start and finish times.
• The permit should also confirm that:
1. all combustible materials have been removed from the area or protected with non-combustible materials;
2. suitable and serviceable fire extinguishers are provided;
3. a fire watch is in place for a specified period during and after the work.
• A competent person should be designated to oversee fire safety for all hot works.
• This person should assess whether the work presents an increased fire risk.
• The assessment should include:
1. risks of burns, smoke or toxic fume inhalation;
2. potential harm to people beyond the immediate work area, including third parties and building occupants.
• The competent person should liaise with other site users, contractors and occupiers.
• They should also ensure that hot works do not interfere with fire detection or fire suppression systems.

Furthermore, the terminals and warehouses should implement a formal permit-to-work system for high-risk tasks such as hot works. This means that hot works should only be carried out once a permit has been issued, either in physical or digital form and all specified conditions have been satisfied.

Moreover, a designated competent person should be present to physically oversee the hot works, ensuring full compliance with the permit-to-work requirements and preventing unauthorised access to the area, using barriers where necessary.

The permit-to-work conditions should specify that all hot works are stopped at least one hour before the end of the working day, or two hours in high-risk areas such as near flammable cargo. A fire watch should be maintained during and for a minimum of one hour after hot works, extended to two hours in high-risk areas. Fire watch duties need to be comprehensively handed over in the event of shift change.

Effective communication and training is key: Fire safety procedures and hot works controls should be routinely included in shift briefings and site inductions for both internal staff and visitors. Any updates or changes that could impact operations should be communicated promptly.

It is essential to ensure that all personnel remain competent and fully aware of current fire safety requirements. Operators should also consider implementing targeted training and accreditation programs for those directly involved in hot works.