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Excessive Hot Work May Signal Workplace Safety Culture Issues

Welder welding in hot work PPE

Hot work, a term that encompasses a variety of specific maintenance activities such as welding, cutting, and brazing, is instrumental in numerous industries for the upkeep of equipment and machinery. However, the utilization of hot work is not without its hazards. As a safety professional, I've borne witness to cases where hot work became the default for most repairs, even under conditions with a significant fire risk. This tendency hints at a concerning issue - a safety culture that might be too tolerant of high-risk practices. In this blog post, we'll delve into scenarios where hot work may be overused and offer valuable insights and practical tips on ways to enhance maintenance and repair safety in the workplace and improve the company's safety culture in the process.

Hot Work's Design and Maintenance Issues

The Issue of Design

Threee workers working on design plans

One of the core reasons maintenance teams might find themselves increasingly resorting to hot work is the prevalent issue of machinery being operated beyond its designed capacity. This is particularly prevalent in scenarios where there's a high degree of load stress exerted on the machine. Overuse can trigger frequent breakdowns, prompting a need for swift, immediate solutions to minimize downtime. It is in these instances that hot work, primarily welding, becomes the go-to repair method.

The rationale behind this is simple and seemingly practical: if a quick weld can fix the issue in less than 5 minutes, why not opt for this method? However, the problem arises when such repairs become a regular occurrence. These seemingly inconsequential 5-minute repair jobs, if occurring multiple times a week, can quickly add up. Over-reliance on hot work not only portrays a reactive approach towards maintenance but also signals a lenient safety culture that could potentially endanger workers and the workplace.

Furthermore, if hot work is being executed in an industry that's particularly susceptible to fire, every 5 minutes or less hot work job is an opportunity for things to go awry. Dealing with a potential fire hazard each time a quick-fix repair is carried out is the equivalent of playing with fire - quite literally - and the odds of an incident increase with each occurrence.

Beyond the fire risk, consider the impact frequent equipment failure has on productivity. If the machinery is constantly breaking down, inevitably, work efficiency is compromised. Persisting with the quick-fix approach of hot work not only puts lives at risk but also detrimentally affects the overall performance and productivity of the workplace.

The question then arises: why not invest real effort and thought into solving the true problem? It's essential to examine the root causes of these frequent breakdowns and address them directly. Investing in proper equipment maintenance, redesigning machinery that's being over-taxed, or even replacing equipment where necessary is likely to be much more beneficial in the long run. It’s not just about improving workplace safety, but also contributing positively to the company's efficiency and establishing a proactive, rather than reactive, safety culture.

Running Equipment to Failure

Man with broken down car

Another issue that exacerbates the over-reliance on hot work is the practice of running machinery to failure. This approach turns minor issues, which would require little downtime, effort, or cost to address, into major problems that demand significantly more resources to rectify. As a result, hot work jobs that were supposed to take minimal time now stretch into lengthy procedures. Even if these comprehensive repairs occur less frequently than the smaller, design-related issues, the extended duration of such work can offset the potential decrease in frequency. Implementing a routine maintenance schedule to address minor issues before they escalate is a proactive tactic that can maximize uptime, minimize the need for hot work, and enhance overall safety. This approach not only mitigates risk factors but also fosters a culture of safety and preparedness.

In industries particularly prone to fire hazards, such as woodworking or fuel companies, initiating hot work can be a substantial endeavor due to the presence of significant amounts of flammable or combustible materials in the work area. The presence of combustible dust, for example, necessitates thorough removal procedures before hot work can commence. Similarly, bulk fuel or oil storage tanks require protective shielding to prevent any accidental ignition during hot work procedures. And remember, this is merely the preparatory phase! There's a plethora of additional safety measures that need to be adhered to during the actual hot work process to ensure the maintenance of a safety culture and safeguard the workplace.

Cold Methods Consideration

Water Jet Cutter

A lack of consideration for cold methods often stems from a safety culture overly reliant on hot work. Cold methods, such as non-sparking saws and high-pressure water saws, can be highly effective, but they are also frequently costlier initially than more traditional methods like a cutting torch. It's analogous to why we don't see concrete being more widely used for roads. Concrete, with its superior compressive strength and longevity, still isn't always chosen over asphalt due to its substantial upfront costs.

These initial expenditures can cause hesitation, leading to an evaluation of whether cold methods are economically viable. If deemed too costly, we find ourselves reverting back to hot work, despite the prevalent fire risks in some industries. While businesses need to think long-term, they cannot afford to be hamstrung by short-term costs to such a degree that their long-term viability is jeopardized. Thus, in spite of the known risks, hot work remains a common practice.

Alternative Repair Methods

Flow Chart of Options

In my experience, while examining various pieces of equipment, I've encountered scenarios that left me puzzled. Take for example a piece of equipment that required its anchoring clamps to be cut out annually to replace the rods due to normal wear and tear. This situation led me to question why the implementation of a durable bolt-on clamp system was not considered - something that could easily be unbolted during the rod replacement process. It seems such an idea was never entertained. Consequently, this got me investigating areas prone to frequent damage and whether it would be possible to repair these in a modular way. Could we create a method that allows for the simple removal and secure reattachment of new sections? While it's understood that this approach might not be suitable in all situations, that doesn't negate its potential utility where its implementation is feasible.

There's no denying that hot work serves a purpose in fabricating sections, anchoring systems, and other similar constructs. However, these hot work processes can be safely conducted in a designated area within the company, specifically designed and maintained to be fire-proof. This is a safer alternative to performing these tasks amidst more vulnerable machinery. Once these pieces are fabricated, they are then carefully secured in the field without the need for any on-site hot work, such as arc striking or torch lighting.

The solutions to these challenges often lie in our perspective and creativity. By taking a step back and analyzing the situation from a different vantage point, we can identify innovative solutions that minimize reliance on hot work, subsequently mitigating the associated hazards. An uncontrolled fire can be an extreme consequence of hot work, causing significant damage to the workplace. This, in turn, hampers productivity, which is contrary to your ultimate goal. Therefore, it's paramount to cultivate a safety culture that prioritizes workplace safety, effectively balancing costs, productivity, and safety.


Hot work, while an effective solution to certain maintenance and repair issues, is not always the optimal choice, particularly in businesses with high fire vulnerability. Relying on it too much likely signals your safety culture may need some improvement. Hot work may seem like a quick fix, but it comes with its own set of risks. Consequently, it is essential to invest in equipment design with due diligence to lessen the need for frequent repairs, which in turn, reduces the dependence on hot work. It's about proactive planning rather than reactive responses - scheduling planned downtime to address minor repair issues before they escalate can actually lead to an overall increase in uptime, as opposed to running equipment until it fails.

Exploring alternatives to hot work, such as cold methods, can significantly mitigate associated hazards. However, it's essential to acknowledge that these cold methods are not risk-free either, underlining the importance of comprehensive risk assessment and management strategies. By thinking outside the box, you can leverage hot work in safe, controlled environments for effective fabrication of solutions, which are then implemented in the field. This innovative approach to problem-solving not only minimizes the risks linked with hot work but also ensures the smooth and efficient running of the business operations for which you are responsible. As you continuously improve in this aspect, you enhance your company's safety culture, propelling the business towards greater heights of success.

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