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Welding and fabrication · United Kingdom

Method statement for hot works welding

By Safety PaperworkBuilt from HSE guidance and CDM 2015 · How we write and check theseUpdated

You must assess the risks of hot works welding and record the significant findings if you employ 5 or more people. On CDM sites the principal contractor will ask for RAMS before you start.

RAMS cover the hazards, who could be harmed and how, the controls and the safe sequence of work, and the crew is briefed and signs. The main hazards are welding and cutting fumes, fire from hot works, public entering the work area and electric shock from leads and power tools.

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RAMS example: hot works welding

This is a complete RAMS for hot works welding, with 6 job steps. Open it in the builder to add your site, crew and signatures, change anything, and download a PDF. Or download the free Word template below and fill it in by hand.

Risk Assessment and Method Statement (RAMS)
On-site welding · Welding and fabrication · Example
Document RAMS-001 · Rev 1

Risk assessment

#ActivityHazardsWho might be harmedRisk beforeControlsRisk after
1Get a hot work permit and clear flammables from the area
  • Fire from hot works
  • Flammable liquids and gases
Workers, Occupants, PublicVery high (15)
  • Use cold work methods where you can, such as bolting, press fittings or cutting with a saw instead of a torch. Eliminate
  • Move anything that can burn at least 10 metres away, or cover it with fire blankets. Isolate
  • Fire from hot works: see step 6 for the full controls Control (procedures)
  • Use non-flammable or water-based products where you can. Reduce / substitute
  • Keep ignition sources away: no smoking, no hot work and no running engines near flammables. Isolate
  • Store fuels and solvents in approved, closed containers in a ventilated area away from the work. Control (engineering)
  • Refuel equipment outdoors with the engine off and cool. Control (procedures)
  • Keep only what you need for the day on site. Control (procedures)
  • Store gas cylinders upright, secured and outdoors. Control (procedures)
  • Keep a suitable fire extinguisher where flammables are used or stored. Control (procedures)
  • Wear chemical gloves and safety glasses when pouring or mixing. PPE
Medium (5)
2Set up welding screens to protect others from arc flash
  • Eye injuries
  • Public entering the work area
Workers, People nearby, Public, ChildrenHigh (12)
  • Use tool guards and screens to stop flying particles. Control (engineering)
  • Use dust extraction and water to keep dust out of the air. Control (engineering)
  • Keep others out of the area when cutting, grinding or chipping. Control (procedures)
  • Keep an eye wash station or eye wash bottles on site. Control (procedures)
  • Wear safety glasses at all times, goggles for dust and chemicals, and a face shield for grinding. PPE
  • Fence off the site with secure temporary fencing and lock the gates when you leave. Isolate
  • Give pedestrians a safe, marked path around the work, with ramps for prams and wheelchairs. Isolate
  • Use hoarding, covered walkways or catch fans where work is above public areas. Control (engineering)
  • Put signs at each entry: site name, contact number and "No unauthorised entry". Control (procedures)
  • Make the site safe at the end of each day: cover holes, lower plant, remove ladders and lock tools away. Control (procedures)
  • Use a spotter when moving plant or materials across public paths. Control (procedures)
Low (4)
3Check leads and earth clamp, keeping leads dry
  • Electric shock from leads and power tools
  • Slips and trips
Workers, Visitors, PublicHigh (12)
  • Use battery-powered tools where you can. Reduce / substitute
  • Use 110V tools through a centre-tapped transformer, or battery tools. Use an RCD on any 230V supply. Control (engineering)
  • Keep leads off the ground and out of water, using lead stands or hooks. Control (engineering)
  • Check leads, plugs and tools before every use. Tag out and remove anything damaged. Control (procedures)
  • Keep tools and leads inspected and PAT tested on a regular schedule. Control (procedures)
  • Do not use tools in rain or wet areas unless they are rated for it. Control (procedures)
  • Wear safety boots and dry gloves. PPE
  • Plan walkways and keep them clear of materials, hoses and leads. Eliminate
  • Run leads and hoses overhead on hooks or stands, or along walls, not across walkways. Control (engineering)
  • Fill or cover holes, and lay boards or mats on muddy access paths. Control (engineering)
  • Clean up offcuts, packaging and spills as you go, not at the end of the day. Control (procedures)
  • Keep work areas, stairs and access paths well lit. Control (procedures)
  • Wear safety boots with good grip, laced up. PPE
Low (4)
4Weld with fume extraction or a respirator, especially on galvanised steel
  • Welding and cutting fumes
  • Burns from hot surfaces
Workers, People nearbyVery high (16)
  • Remove paint, galvanising and coatings from the weld area first, or use a process that makes less fume. Reduce / substitute
  • Use fume extraction (local exhaust ventilation) close to the weld. Control (engineering)
  • Weld outdoors or in a well-ventilated area, and keep your head out of the fume plume. Control (engineering)
  • Do a COSHH assessment. HSE expects fume extraction for all indoor welding, including mild steel. Control (procedures)
  • Never weld or cut in a confined space without testing the air and using forced ventilation. Control (procedures)
  • Wear a powered air respirator or fitted respirator when extraction is not enough. PPE
  • Wear a welding helmet, welding gloves and flame-resistant clothing. PPE
  • Isolate heating systems and let parts cool before you touch them. Eliminate
  • Fit guards or insulation on hot pipes and equipment. Control (engineering)
  • Mark hot items with chalk or a "HOT" sign so others know. Control (procedures)
  • Keep a first aid kit and cool running water nearby for burns. Control (procedures)
  • Wear heat-resistant gloves and long sleeves. PPE
Medium (8)
5Grind welds with guards on
  • Angle grinder injuries
  • Loud noise
  • Eye injuries
Workers, People nearbyHigh (12)
  • Use a guarded saw or a different tool where you can. Reduce / substitute
  • Keep the guard on and use the side handle. Never remove the guard. Control (engineering)
  • Use the right disc for the job, rated for the grinder's speed. Check it for cracks first. Control (procedures)
  • Only trained people change discs, with the grinder unplugged or the battery out. Control (procedures)
  • Keep both hands on the grinder and let the disc stop before putting it down. Control (procedures)
  • Use quieter tools and methods, such as cut-to-size materials, low-noise machines and battery tools. Reduce / substitute
  • Keep noisy plant away from work areas, and use screens or distance between the noise and people. Isolate
  • Keep tools maintained and use mufflers on compressors and generators. Control (engineering)
  • Limit time on noisy tools and rotate workers. Control (procedures)
  • If you have to shout to be heard by someone 2 metres away, the noise is probably 85 dB(A) or more: wear hearing protection. Control (procedures)
  • Assess noise. At 85 dB(A) or more, hearing protection is required and the zone must be marked. Control (procedures)
  • Eye injuries: see step 2 for the full controls Control (procedures)
Medium (8)
6Fire watch after finishing, then sign off the permit
  • Fire from hot works
  • Fire and emergencies
Workers, Occupants, Public, VisitorsVery high (15)
  • Use cold work methods where you can, such as bolting, press fittings or cutting with a saw instead of a torch. Eliminate
  • Move anything that can burn at least 10 metres away, or cover it with fire blankets. Isolate
  • Use fire-resistant screens to stop sparks reaching people or gaps in walls and floors. Control (engineering)
  • Get a hot work permit before starting. Control (procedures)
  • Keep a charged fire extinguisher and fire blanket at the work spot. Control (procedures)
  • Keep a fire watch during the work and for at least 60 minutes after you finish. Control (procedures)
  • Check for smouldering behind walls, in ceilings and under floors before you leave. Control (procedures)
  • Wear flame-resistant clothing, welding gloves and eye or face protection. PPE
  • Provide fire extinguishers suited to the site, checked and easy to reach. Control (engineering)
  • Keep exits and escape routes clear and signed. Control (engineering)
  • Have a site emergency plan: alarm, exits, assembly point and emergency contacts. Control (procedures)
  • Keep a stocked first aid kit and at least one trained first aider on site. Control (procedures)
  • Know the site address and how emergency services get in. Call 999. Control (procedures)
  • Go through the emergency plan with every worker and visitor at induction. Control (procedures)
  • Keep flammable materials and rubbish away from exits and escape routes. Control (procedures)
Medium (5)

Method statement: sequence of work

  1. Get a hot work permit and clear flammables from the area
  2. Set up welding screens to protect others from arc flash
  3. Check leads and earth clamp, keeping leads dry
  4. Weld with fume extraction or a respirator, especially on galvanised steel
  5. Grind welds with guards on
  6. Fire watch after finishing, then sign off the permit

PPE

Welding helmetWelding gauntletsSafety bootsCoverallsHalf-mask respirator (P3 filters)Ear defendersFace shieldSafety glassesSafety gogglesHi-vis vestRigger glovesCut-resistant gloves

Plant and equipment

Welding setAngle grinder (disc cutter)Generator (110V site transformer)

Permits and plans

Hot works permit (fire watch at least 60 minutes after)

Emergency

Call 999. Add the nearest A&E, the assembly point and the first aider for your site.

Sign-off

Supervisor and every worker sign to confirm they have read and understood this RAMS.

Free RAMS template for hot works welding

Word (.docx) and PDF, A4 landscape, no email needed. Fill in your site details, then print or send it.

Word template (.docx)PDF template

Make yours in 2 minutes

Same document, filled in for your job. Answer a few yes or no questions, the crew signs on the phone, and you send the PDF.

Start this RAMS

Pre-start checklist for hot works welding

Tick these off before work starts. They come from the hazards, permits and equipment in this job.

The safe sequence of work

  1. Get a hot work permit and clear flammables from the area
  2. Set up welding screens to protect others from arc flash
  3. Check leads and earth clamp, keeping leads dry
  4. Weld with fume extraction or a respirator, especially on galvanised steel
  5. Grind welds with guards on
  6. Fire watch after finishing, then sign off the permit

Hazards to watch on hot works welding

The hazards most specific to this job, and the step where each one comes up.

Step 4Welding and cutting fumesWelding, cutting and brazing give off metal fumes and gases that damage the lungs and can cause cancer.
Step 4Burns from hot surfacesTouching hot pipes, tools, bitumen, solder or freshly welded metal burns the skin.
Step 1Flammable liquids and gasesPetrol, solvents, thinners and LPG catch fire or explode when vapour reaches a spark, flame or hot surface.
Step 5Angle grinder injuriesThe disc shatters, binds or kicks back, causing deep cuts to legs and hands or eye injuries.
Step 6Fire and emergenciesA fire, injury or other emergency happens and workers cannot get out, raise the alarm or get first aid in time.
Step 3Electric shock from leads and power toolsDamaged leads, plugs or tools, or water near power, give the user an electric shock.
Very likelyLikelyPossibleUnlikelyVery unlikelyHow bad it could be: Negligible to FatalBA
Highest risk on hot works welding: Very high before controls (B), down to Medium after controls (A), on the United Kingdom 5 by 5 risk matrix (likely and major injury becomes unlikely and major injury).

What changes on your site

This example covers the job itself. Your site may add more. Add controls for any of these that apply (the builder asks you these as yes or no questions):

  • Will anyone work at height, anywhere a fall could hurt them?
  • Will anyone use a ladder or stepladder?
  • Will anyone work on a roof?
  • Is there a fragile roof, skylight or clear roof sheet?
  • Will you use a scaffold or mobile tower?

Why RAMS get rejected

Principal contractors send documents back for these reasons. This example avoids them, but check yours too.

  • The method statement is only a list of headings that repeats the risk table and never says how the work is done.
  • The method sequence does not match the risk assessment, for example the method strips the roof before the scaffold is handed over.
  • Residual risk is still High after controls with no extra measures or explanation.
  • It reads as copied: another firm, another address, or wording that does not fit UK sites. HSE warns that copying an example and adding your name does not satisfy the law.
  • Work on an older building with no reference to an asbestos survey.
  • Plant and access equipment listed with no inspection, thorough examination or competence evidence.
  • No briefing record, no revision history, or no named supervisor.

Questions

Do I need RAMS for hot works welding?

You must assess the risks of hot works welding and record the significant findings if you employ 5 or more people. On CDM sites the principal contractor will ask for RAMS before you start.

Who signs the RAMS?

The person who wrote it and the person who approved it sign and date it. Every worker signs the briefing register after it is explained to them, and the principal contractor reviews and accepts it before you start.

How long do I keep it?

Keep this RAMS, every revision and the signed briefing register with the site file for the length of the job, and keep a copy in your records afterwards.

What PPE is needed for hot works welding?

Usually Welding helmet, Welding gauntlets, Safety boots, Coveralls, Half-mask respirator (P3 filters), Ear defenders, Face shield, Safety glasses, Safety goggles, Hi-vis vest, Rigger gloves, Cut-resistant gloves. The site rules may add more, so check with the principal contractor.

More welding and fabrication RAMS

RAMSStructural Steel Erection9 stepsRAMSSteel Fabrication6 stepsRAMSRSJ Installation5 stepsRAMSSteel Handrail Installation5 stepsRAMSGas Cutting5 steps

Related jobs in other trades

DemolitionSoft StripAlso involves fire and emergenciesRoofingRe-RoofingAlso involves public entering the work areaBricklayingBrickworkAlso involves eye injuriesElectricalConsumer Unit ReplacementAlso involves electric shock from leads and power toolsScaffoldingScaffold ErectionAlso involves public entering the work area

Toolbox talks for this job

Toolbox talkOverhead Power LinesToolbox talkExtension Leads and Power ToolsToolbox talkHearing Protection and NoiseToolbox talkSlips, Trips and Falls

Blank RAMS template: free RAMS templates. Also for other countries: Australia (SWMS) · United States (JHA) · Canada (FLHA)

Sources