Factory Fire Safety During Hot Work Operations

Factory Fire Safety During Hot Work Operations

Hot work like welding and cutting carries serious fire risk, especially in industrial settings. Just one stray spark or missed hazard can lead to costly damage or downtime.

But safety isn’t just about having the right tools. It’s about recognising risks, managing the environment, and being ready to respond if something goes wrong.

Good ventilation, clearing combustibles, and following solid safety protocols all matter, but what does that look like in practice?

Let’s break down the practical steps that help prevent fires and protect your people, site, and operations.

Understanding Hot Work Hazards

In factories and industrial settings, hot work like welding, cutting, or grinding brings an immediate fire risk. Sparks, high heat, and nearby flammables can quickly become a dangerous combination.

Staying safe starts with knowing your surroundings. Scan the area: are there materials like wood, cardboard, flammable liquids, or fine dust? Combustible dust is one of the most commonly overlooked risks, yet it can fuel fires and even explosions if left unmanaged.

According to Zurich Insurance, hot work accounts for 15% of all fires in commercial and industrial properties in the UK.

Where possible, remove combustibles altogether. If they can’t be moved, shield them with flame-retardant covers or heat barriers to reduce exposure.

Proper airflow is just as important. Without it, heat, fumes, and flammable vapours can quickly accumulate, especially in confined areas, increasing the risk of ignition and harmful exposure. Use extraction systems, fans, or open access points to keep the air moving and the environment safe.

Look out for ignition sources beyond your tools, think space heaters, damaged cables, or even static discharge. It only takes one to start a fire.

Extinguishers, blankets, and fire alarms should be clearly marked, maintained, and close at hand. Everyone on site should know how to use them, before an emergency happens.

And remember, always keep escape routes clear. In a crisis, every second counts.

This isn’t just compliance. Spotting and managing these risks is the backbone of a workplace that puts safety first, and keeps people and production protected.

Own or a UK Based Factory? Give us a call on 0800 999 11 25 to see how we can help

Importance of Proper Training

Proper training is the foundation of safe hot work. Without it, the job becomes guesswork, and that’s when accidents happen. With the right knowledge, your team can recognise hazards, follow safe systems, and act with confidence when it counts.

Training isn’t just about knowing the tools; it’s about understanding the materials you work with, spotting fire risks, and committing to a culture of safety. You’ll learn exactly what PPE is needed for each task, and why it’s essential for your well-being. Plus, you’ll be prepared for any emergency, and when every second counts, that preparedness can make all the difference.

Compliance with local regulations and industry standards is a fundamental aspect of your training. Knowing and understanding these rules not only protects you but also shields your coworkers and the entire workplace from potential risks. Also, regular fire safety training helps ensure everyone is prepared for fire emergencies, while at the same time, improve the overall safety culture.

In a nut-shell, committing to proper training provides you with the knowledge and skills to carry out hot work safely. It creates a safety-driven environment where accountability thrives, leading to a safer and more efficient workplace.

Implementing Safety Protocols

In the year ending March 2024, 49,835 fire safety audits were completed in England, with only 58% deemed satisfactory – the lowest proportion since 2011.

Having a solid foundation in training sets the stage for implementing effective safety protocols in hot work environments. Identify potential fire hazards, and make certain that all workers understand the risks associated with welding and cutting processes.

Develop and document thorough safety protocols tailored to your workplace. Your fire strategy plan should outline necessary precautions, equipment inspections, and emergency procedures.

Make certain workers are equipped with personal protective equipment (PPE) such as flame-resistant clothing, safety goggles, and gloves. Regularly inspect this gear for wear and tear to guarantee it remains effective.

• Establish clear communication channels, so everyone knows who to contact in case of an emergency.
• Conduct routine safety meetings to reinforce the importance of adhering to these protocols.

You should also confirm compliance with relevant regulations, such as those outlined by OSHA.

Regular audits and drills will help maintain awareness and readiness among your team. Learn more about our fire risk assessments.

Fire Watch: A Critical Line of Defence

When hot work is underway, a fire watch isn’t just a box-ticking exercise, it’s a frontline safeguard. The role is about active presence, sharp awareness, and immediate action. If a fire does break out, seconds matter. That’s why fire watch duties are essential to keeping people safe and operations protected.

Fire Strategy – Are you Accountable? – Speak to an Expert

If you’re on fire watch, here’s what matters most:

1. Stay alert, stay focused.

Keep a constant watch on the area during and after hot work. Sparks travel further than you think — so don’t just scan the work zone; monitor the wider surroundings too. Look out for early signs of ignition, and never assume “someone else” will notice.

2. Clear, calm communication.

You’re the eyes and ears for the hot work team. If something doesn’t look right, speak up immediately. Make sure you know who to contact and how to raise the alarm. Fast communication is often the first trigger for a safe response.

3. Know your kit.

You must have access to suitable fire extinguishers, and know how to use them. That means more than spotting them on a wall. Check that they’re serviced, appropriate for the type of fire risk, and within easy reach.

A solid fire watch isn’t just about responding to incidents, it’s about preventing them. Done properly, it’s one of the simplest and most effective layers of protection during hot work.

Want to go deeper? Take a look at our guide on improving fire safety in UK factories — it’s packed with practical insight on compliance, best practices, and creating safer industrial environments.

Selecting the Right Equipment for Hot Work

Having the right kit for the job isn’t just about productivity, it’s about protection. From torches to PPE, making sure your tools meet recognised safety standards is fundamental. If you’re unsure your setup would stand up to scrutiny, take a look at our guide on how to pass a fire safety inspection in your factory, it’s packed with practical steps to help you stay compliant and safe.

Each type of hot work comes with its own risks, so your gear needs to match the job. Whether it’s welding, cutting, or grinding, choose tools that are purpose-built and properly certified.

Always inspect your equipment before use. That includes checking for wear and tear, making sure everything is working correctly, and confirming that your personal protective equipment (PPE), gloves, flame-resistant clothing, face shields, is up to the task.

Maintaining a Safe Work Environment

A safe work environment is the foundation of effective hot work safety. When welding, cutting, or grinding, it doesn’t take much, a spark, a flammable item, or a lapse in attention, for a small incident to become something more serious. That’s why staying proactive and consistent in your approach matters.

Here are a few core practices that help minimise fire risk:

• Good housekeeping 
• Effective ventilation
• Proper equipment use 
• Clear escape routes

Just as important is making sure your team is properly trained. That means more than knowing how to use a tool, it’s about recognising hazards, reacting quickly to emergencies, and following site-specific fire safety procedures with confidence.

Regular fire drills, toolbox talks, and walk-throughs of your fire strategy aren’t just good habits — they’re essential in embedding a safety-first mindset across the team.

Because when things go wrong, preparation makes all the difference.  

That’s where a strong emergency response plan comes in

Emergency Response Planning

When hot work is taking place, having a clear and well-rehearsed emergency response plan isn’t just best practice, it’s critical. Fires, injuries, or chemical spills can escalate fast if there’s uncertainty or hesitation, so everyone on site needs to know exactly what to do if things go wrong.

That means outlining clear procedures for a range of scenarios, whether it’s evacuating safely in the event of a fire, administering first aid for an injury, or containing a chemical spill until the HAZMAT team arrives.

Just having a plan isn’t enough. Regular training sessions, walkthroughs, and emergency drills are vital to make sure people aren’t just familiar with the process, they’re confident in it.

It’s also important to define roles and responsibilities in advance, so there’s no confusion about who’s doing what during a real incident. And as your site evolves, with new people, equipment, or layouts, so should your plan. Keeping it up to date ensures your response remains sharp.

Effective emergency planning goes hand in hand with evacuation strategies. If a site needs to be cleared, routes should be marked, clear of obstructions, and known to everyone involved in hot work. Planning ahead like this doesn’t just reduce risk — it builds a culture of readiness that can make all the difference when seconds count.

Conclusion

Prioritising hot work safety isn’t just best practice, it’s business-critical. From recognising risks and wearing the right PPE to carrying out proper fire watch and sticking to clear procedures, every step plays a part in preventing fires and keeping people safe.

Investing in training, maintaining your workspace, and staying prepared for emergencies builds a culture where safety becomes second nature. It’s not about ticking boxes, it’s about making sure everyone gets home safe at the end of the day.

Stay alert. Stay informed. And make safety part of the way you work, every single time.

If you have any questions or would like to talk to us about fire safety at your factory, give us a call on 0800 999 11 25 or drop us a message

My Fire Safety. Co-Space, 25 Town Square,
Stevenage, SG1 1BP. 

Related Fire Safety Training Courses:

Fire Extinguisher Training
Regular Refresher Training
Fire Marshal Training
Fire Alarm Training