When this template fits
This welding hot works RAMS is for mechanical and fabrication contractors carrying out arc or gas welding on site — pipework, structural steel, brackets and plant connections. If the principal contractor or client has asked for a hot works risk assessment before issuing you a permit, this is the document they expect to see, and it must account for the fact that welding fume is now treated as a carcinogen. It gives you the recognised hazards, fume controls and permit interface so the competent person signing it can confirm it matches the real job.
What this RAMS includes
- ✓ 9 task-specific hazards scored on a 5×5 matrix (initial → residual)
- ✓ Specific control measures for each hazard, in hierarchy-of-control order
- ✓ A 10-step method statement (sequence of works)
- ✓ PPE, plant/equipment, permits and competence requirements
- ✓ Emergency arrangements and operative briefing / sign-off section
Scope of works
Arc/MIG/TIG welding with associated fire, fume and UV risk.
Sequence of works
- 1PLAN AND PERMIT: Review RAMS and COSHH assessments. Identify base materials and coatings. Obtain a signed hot works permit. Confirm with site fire marshal that escape routes are clear and detection systems are managed.
- 2PREPARE THE AREA: Clear combustibles to at least 5 m from weld zone or protect with fire-resistant welding blankets. Erect welding screens/curtains around the work area. Position fire extinguisher and fire blanket within immediate reach.
- 3SET UP EQUIPMENT: Inspect welding machine, cables, electrode holder and return clamp for damage before connecting to power. Fit voltage reduction device on AC sets in damp areas. Confirm shielding gas cylinder is secured upright on a trolley with correct regulator.
- 4VENTILATION: Confirm LEV is operational and positioned within 300 mm of the weld point. For indoor or enclosed work, verify general forced ventilation is active. Do not commence welding until adequate fume extraction is confirmed.
- 5DON PPE: Welder and any assistant to put on all required PPE — welding helmet, flame-resistant jacket, leather gauntlets, spats, safety boots and RPE — before striking the arc.
- 6WELD: Strike arc/commence welding. Maintain controlled technique to minimise spatter. Fire watcher monitors the area throughout. Periodically check for fume build-up and ensure LEV remains effective.
- 7PAUSE AND BREAKS: When stopping welding (breaks, material changes), park the electrode holder or MIG torch safely, turn off the welding set, and maintain fire watch. Mark hot workpieces clearly as 'HOT'.
- 8POST-WELD INSPECTION: On completion, allow weld to cool. Fire watcher inspects all areas within 10 m for any sign of smouldering, heat or smoke for a minimum of 60 minutes. Check above, below and on the other side of any penetrated surface.
- 9CLOSE OUT: Reinstate any disabled fire detection systems and confirm with fire marshal. Remove welding screens and equipment. Secure gas cylinders. Record completion on hot works permit and sign off.
- 10HOUSEKEEPING: Dispose of electrode stubs, slag and waste wire in a non-combustible container. Return site to safe condition. Report any near-misses, incidents or equipment defects.
Hazards, risk rating & controls
Risk = likelihood × severity (1–25). Initial is before controls; residual is with controls applied.
Welding fume inhalation
Who’s at risk: Operatives, Other trades on site
- › Fit on-torch LEV extraction or position a capture-hood LEV unit within 300 mm of the weld point to extract fumes at source before they reach the welder's breathing zone.
- › Where LEV alone is impractical, supplement with forced general ventilation (fans/air movers) to dilute residual fume below WELs. Never rely solely on dilution ventilation for stainless or coated materials.
- › Conduct COSHH assessment identifying base metal, coatings and consumables. Arrange air monitoring to confirm exposure remains below WELs (e.g. manganese 0.2 mg/m³ TWA). Review if consumables or process change.
- › Where LEV/ventilation cannot adequately control fume exposure, provide and enforce use of a tight-fitting half-mask with P3/ABEK P3 filter or powered air-purifying respirator (PAPR) as selected by a competent person.
Fire and explosion from hot works
Who’s at risk: Operatives, Other trades on site
- › Issue a hot works permit before any welding commences. Permit must identify hazards, confirm precautions, nominate a fire watch and state a post-work monitoring period of at least 60 minutes (preferably longer).
- › Remove or relocate flammable and combustible materials to at least 5 m from the weld area. Where removal is impossible, protect with non-combustible welding blankets or fire-resistant boards.
- › A dedicated fire watcher must monitor the work area throughout welding and remain for a minimum of 60 minutes afterwards, checking for smouldering materials. Fire extinguisher must be immediately available.
- › Position a CO2 or dry powder extinguisher (minimum 2 kg) and a fire blanket within immediate reach of the welder. Operatives must be trained in use.
UV and IR radiation (arc eye / skin burns)
Who’s at risk: Operatives, Other trades on site
- › Erect opaque welding screens or dark-tinted retractable curtains around the weld bay to prevent arc radiation reaching bystanders and adjacent workers.
- › Welder must wear a compliant auto-darkening welding helmet with minimum shade DIN 9 (MIG) or DIN 10–12 (arc/TIG), conforming to EN 379. Passive fixed-shade helmets are acceptable if shade rating is verified for the process.
- › Welder must wear flame-resistant long-sleeve jacket/coverall (EN ISO 11611) and leather welding gauntlets. No exposed skin within the arc radiation zone.
Electric shock from welding equipment
Who’s at risk: Operatives, Other trades on site
- › Before use, inspect the welding set, electrode holder, return clamp and all cables for damage, bare conductors, loose connections or deteriorated insulation. Tag and remove defective equipment from service.
- › Fit a voltage reduction device on AC arc welders, reducing open-circuit voltage to ≤25 V when not welding, especially in damp or confined locations.
- › Welder must stand on an insulating rubber mat and keep welding gauntlets dry. Never weld with wet gloves or standing in water.
Burns from hot metal and spatter
Who’s at risk: Operatives, Other trades on site
- › Allow workpieces to cool before handling or mark clearly with 'HOT' chalk or crayon. Do not apply water to hot welds as this can cause thermal cracking and steam burns.
- › Welder and any assistant must wear EN ISO 11611 Class 2 flame-resistant jacket/coverall, leather gauntlets and leather spats/boot covers to protect against spatter.
Noise from welding and grinding
Who’s at risk: Operatives, Other trades on site
- › Where practicable, use quieter cutting/preparation methods (e.g. cold saw, jig cutting) in place of angle grinding for weld preparation.
- › Establish a designated exclusion zone around grinding/cutting activities so non-essential workers are not exposed to noise above 80 dB(A). Use signage and barriers.
- › Provide and enforce use of EN 352 compliant ear defenders (minimum SNR 20) or ear plugs when noise at the ear exceeds 80 dB(A). Mandatory above 85 dB(A).
Hazardous substances in coatings and base materials
Who’s at risk: Operatives, Other trades on site
- › Before welding, identify surface coatings by checking material records or using test kits. Mechanically remove coatings for at least 150 mm each side of the intended weld zone before commencing. Competent person to review results.
- › Where coatings cannot be fully removed, increase LEV extraction rate and upgrade RPE to PAPR or full-face respirator with appropriate combination filter. Reduce exposure time through task rotation.
- › Obtain Safety Data Sheets for all welding consumables (rods, wire, flux). Include identified coating hazards in site COSHH assessment. Review with a competent person before work starts.
Fire spread and escape route obstruction
Who’s at risk: Operatives, Other trades on site
- › Before setting up welding equipment, verify that all designated escape routes remain unobstructed and accessible. Obtain agreement from site fire marshal.
- › Ensure area smoke or heat detectors are operational. Where work temporarily disables detectors (to prevent false alarms), inform site fire marshal, post a fire watch and reinstate detectors immediately after work.
Manual handling of welding plant and materials
Who’s at risk: Operatives, Other trades on site
- › Use trolleys for welding sets and gas cylinders. Use mechanical lifting equipment (crane, forklift, manipulator) for heavy plate or structural sections.
- › Assess all significant manual handling tasks. Where mechanical aids are unavailable, organise two-person lifts and brief operatives on safe technique. Review for musculoskeletal risk.
PPE
- ✓ Safety footwear (EN ISO 20345)
- ✓ Hi-vis clothing
- ✓ Safety gloves (task-appropriate)
- ✓ Hard hat (EN 397) where overhead risk or site rules require
- ✓ RPE (FFP3 or as risk-assessed) with face-fit
- ✓ Eye/face protection
- ✓ Flame-resistant gloves
- ✓ Insulated gloves where live work is unavoidable
- ✓ Hearing protection (to the assessed SNR)
- ✓ RPE per the COSHH assessment
- ✓ Chemical-resistant gloves
Competence
- ✓ Site induction completed; CSCS or equivalent where the site requires it
Schemes (CSCS, PASMA, IPAF…) evidence competence; they are not statutory requirements in themselves.
Plant & equipment
- › Welding set (MMA inverter, MIG/MAG or TIG plant) with RCD-protected supply
- › Local exhaust ventilation unit with capture hood or on-torch extraction
- › Oxy-fuel set with regulators, flashback arrestors and non-return valves
- › Cylinder trolley with restraint straps
- › Welding screens, fire blankets and a CO2 or dry powder extinguisher
Permits & legislation
What principal contractors usually check
- ✓ LEV is specified for ALL welding including mild steel, with RPE as a supplement — not RPE on its own (the post-2019 HSE position)
- ✓ Current LEV thorough examination/test records and welder face-fit certificates are referenced or attached
- ✓ The fire watch duration and who holds it are stated, and combustibles within 10m have a clearance or protection measure
- ✓ The document is site-specific — real address, access arrangements and dates, not a generic template
- ✓ Hazards match the actual task and the controls are specific (not “take care” and “use PPE”)
- ✓ Named supervisor and competent person, with operative sign-off space
- ✓ Emergency and rescue arrangements that work for this site
The report builder runs these as pre-submission checks before you download — or run an existing document through the free RAMS pre-submission checker.
Frequently asked questions
Do I need LEV for welding mild steel, or is a mask enough?
You need LEV. Since the HSE changed its enforcement position in February 2019, all welding fume — including mild steel — is treated as carcinogenic, so general ventilation alone is no longer acceptable. The expectation is engineering control first: local exhaust ventilation at the weld point, indoors or outdoors. RPE such as an FFP3 or powered respirator is required on top of LEV, not instead of it, and only works where the wearer has been face-fit tested. A RAMS that relies on a dust mask alone will be rejected by most principal contractors.
How long does the fire watch need to run after I finish welding?
The fire watch runs for the period set on the hot works permit, which is usually a minimum of 60 minutes after the last spark. Many clients and their insurers require longer — often a full hour of constant watch followed by periodic checks for up to an hour more. The point is that smouldering can take time to develop into a visible fire, especially where hidden combustibles or voids are nearby. Your RAMS should state the duration, name who holds the watch, and confirm extinguishers are kept to hand throughout.
What regulations apply to welding?
Control of Substances Hazardous to Health Regulations 2002 (COSHH), Regulatory Reform (Fire Safety) Order 2005, Management of Health and Safety at Work Regulations 1999, reg 3 — risk assessment are the main ones, alongside Electricity at Work Regulations 1989, Control of Noise at Work Regulations 2005, Manual Handling Operations Regulations 1992. The Health and Safety at Work etc. Act 1974 and CDM 2015 apply to all construction work.
Does a RAMS need to be site-specific?
Yes — this is the most common reason documents get sent back. Principal contractors reject generic copy-paste RAMS. Your document should name the site, access arrangements, dates, supervisor and any site-specific hazards. The RamsDocs builder fills these in for you and flags what's missing before you download.
Is this template free?
Yes — everything on RamsDocs is free during early access, including building a site-specific version of this RAMS and downloading the PDF. No card required.