Hot Work Safety Course

Lesson 1 • Regulatory Framework Overview

Introduces the regulatory bodies and standards governing hot work. Connects compliance obligations to practical worksite responsibilities.

Lesson 2 • Core Hazard Categories

Identifies fire, explosion, toxic exposure, and electrical hazards linked to hot work. Builds hazard recognition skills essential for later risk assessment chapters.

Lesson 3 • Defining Hot Work Operations

Covers the scope of hot work activities and the energy sources involved. Provides baseline vocabulary used throughout the course.

Lesson 1 • Dust and Particulate Explosion Hazards

Addresses combustible dust clouds as a distinct explosion risk during hot work. Prepares workers to recognise and mitigate dust hazards before ignition.

Lesson 2 • Heat Transfer and Ignition Pathways

Describes conduction, convection, and radiation as mechanisms that spread heat from hot work. Identifies ignition pathways workers must control.

Lesson 3 • Flammable and Combustible Materials

Distinguishes flammable from combustible materials by flash point and ignition temperature. Enables workers to classify materials present in hot work zones.

Lesson 4 • Flammable Gas and Vapour Behaviour

Covers flammable limits, vapour density, and dispersion patterns. Explains how gases accumulate in confined or low-lying areas near hot work.

Lesson 1 • Special Location Hazard Considerations

Addresses elevated risk in confined spaces, classified areas, and elevated platforms. Prepares workers to apply additional controls in non-standard locations.

Lesson 2 • Atmosphere Testing and Monitoring

Explains when and how to test the atmosphere for flammable gases and oxygen levels. Ensures workers interpret meter readings correctly before and during hot work.

Lesson 3 • Risk Ranking and Decision Making

Applies likelihood-consequence matrices to prioritise hot work risks. Guides supervisors in deciding whether to proceed, modify, or halt operations.

Lesson 4 • Site Survey and Inspection Techniques

Covers physical inspection of the work area for combustibles, utilities, and structural risks. Establishes the inspection routine used before every hot work permit is issued.

Lesson 1 • Roles and Responsibilities in Permitting

Defines the duties of the permit issuer, authorised performer, and fire watch. Clarifies accountability at each stage of the permit lifecycle.

Lesson 2 • Purpose and Structure of Permit Systems

Explains why permit-to-work systems exist and what components they must contain. Establishes the permit as the central control document for hot work.

Lesson 3 • Completing and Issuing a Permit

Walks through each field of a hot work permit with accuracy requirements. Prevents common errors that invalidate permits or create unsafe conditions.

Lesson 4 • Permit Suspension, Cancellation, and Closure

Covers conditions that require suspending or cancelling an active permit. Ensures workers know how to close out permits and document completion.

Lesson 1 • Hierarchy of Controls Applied to Hot Work

Maps elimination, substitution, engineering, administrative, and PPE controls to hot work scenarios. Establishes the decision logic for control selection.

Lesson 2 • Isolation and Lockout Procedures

Covers energy isolation methods that prevent accidental ignition from adjacent systems. Integrates lockout/tagout principles with hot work preparation.

Lesson 3 • Administrative Procedures and Work Scheduling

Addresses scheduling, communication, and procedural controls that reduce hot work risk. Covers coordination with other trades and shift handover requirements.

Lesson 4 • Combustible Removal and Shielding

Details methods for removing or protecting combustibles within the hot work zone. Reduces ignition probability through physical separation and barriers.

Lesson 1 • Body and Skin Protection

Covers flame-resistant clothing, leather protective gear, and footwear for hot work. Explains material properties that resist ignition, melting, and heat penetration.

Lesson 2 • Respiratory Protection for Hot Work

Identifies fume and gas hazards requiring respiratory protection during hot work. Covers respirator types, fit testing, and limitations in contaminated atmospheres.

Lesson 3 • PPE Inspection, Maintenance, and Storage

Establishes pre-use inspection criteria and maintenance schedules for hot work PPE. Prevents equipment failure caused by damage, contamination, or improper storage.

Lesson 4 • PPE Selection Principles for Hot Work

Applies hazard assessment results to PPE selection decisions. Ensures workers choose equipment rated for the specific thermal, chemical, and optical hazards present.

Lesson 1 • Post-Hot Work Monitoring Requirements

Explains the mandatory monitoring period after hot work stops and why smouldering fires develop. Specifies minimum watch durations and conditions requiring extended monitoring.

Lesson 2 • Fire Prevention Before Hot Work Begins

Covers the pre-work checklist for eliminating ignition sources and protecting combustibles. Establishes the standard of care required before any spark is produced.

Lesson 3 • Fire Extinguisher Selection and Use

Covers fire extinguisher classification, selection for hot work hazards, and the PASS technique. Prepares fire watches to act decisively on incipient fires.

Lesson 4 • Fire Watch Positioning and Responsibilities

Defines where fire watches must be stationed and what they must observe. Clarifies that fire watch is a dedicated role, not a secondary task.

Lesson 1 • Medical Emergency and First Aid Response

Addresses burns, smoke inhalation, and eye injuries common in hot work incidents. Covers immediate first aid actions and handoff to emergency medical services.

Lesson 2 • Root Cause Analysis and Corrective Action

Introduces root cause analysis methods applicable to hot work incidents. Connects findings to corrective actions that prevent recurrence.

Lesson 3 • Fire Emergency Response Procedures

Covers the decision sequence from fire detection through suppression or evacuation. Reinforces the boundary between incipient-stage response and full evacuation.

Lesson 4 • Emergency Action Plan Essentials

Identifies the required elements of an emergency action plan relevant to hot work sites. Ensures every worker knows their role before an emergency occurs.