What is a hot work permit and when is one required?

A hot work permit is a formal written authorisation that must be obtained before any work involving open flames, sparks or heat-producing processes such as welding, cutting, grinding, brazing or soldering. It is required on most Australian construction and industrial sites as part of the permit-to-work system under WHS Regulations. The permit ensures the work area has been inspected, combustibles cleared, fire-fighting equipment positioned and a fire watch assigned. A new permit is needed each day or shift, and whenever the scope, location or personnel change.

How long must fire watch continue after hot work?

Fire watch must continue for a minimum of 30 minutes after the last spark or flame produced by the hot work. Many Australian site safety management plans require 60 minutes or longer for higher-risk work or work in areas with concealed combustibles such as insulation, cable trays or wall cavities. The fire watch person must remain in the area with a serviceable fire extinguisher, monitoring for smouldering, hot spots and unusual smells. The hot work permit must not be closed out until the full fire watch period is complete and a final area inspection confirms no signs of fire.

What distance must be cleared of combustibles before hot work?

Under AS 1674.1 and industry best practice, all combustible materials must be removed or protected within an 11 metre radius of the hot work location. This includes timber, paper, cardboard, oil, grease, solvents, gas cylinders, aerosol cans, plastic sheeting and insulation. Materials that cannot be removed must be covered with fire-resistant blankets or welding screens. Floor sweepings, dust and debris must also be cleared. Wall and floor openings within this radius must be sealed to prevent sparks travelling to adjacent areas.

What atmospheric testing is required before hot work?

Atmospheric testing is required before hot work is performed in any area where flammable vapours, gases or dusts may be present. A calibrated gas detector must measure the lower explosive limit (LEL) and confirm it is below 5% before the permit is issued. Oxygen levels should also be verified. Testing is particularly important near fuel storage, chemical processing, tanks, pipelines, confined spaces and drainage systems. If LEL readings rise during work, the hot work must stop immediately and the area must be ventilated and retested before resuming.

Is this hot work permit template free to use?

Yes. Download and use this hot work permit template for free. Open the file in your browser and use Print then Save as PDF. No MapTrack account is required. If you want digital hot work permits with electronic sign-on, GPS-tagged photo evidence, automated fire watch timers and a complete permit register across all your sites, MapTrack can help. Book a demo to see how it works.

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Free hot work permit template (PDF-ready). Fire watch, atmospheric testing, fire extinguisher placement, isolation and sign-off. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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What is a hot work permit template?

A hot work permit template is a standardised document used to authorise and control any work that involves open flames, sparks, grinding, welding, cutting, brazing or other heat-producing processes on a construction, industrial or maintenance site. The permit establishes a formal approval process that requires the work area to be inspected, combustible materials cleared or protected, fire-fighting equipment positioned, atmospheric testing completed where flammable vapours may be present, and a fire watch person assigned for both the duration of the work and the mandatory post-work monitoring period. Under Australian WHS Regulations, the PCBU has a duty to manage fire risks, and a hot work permit is the standard industry mechanism for demonstrating that duty has been discharged.

Hot work is a leading cause of workplace fires in Australia. Sparks and molten metal can travel more than 10 metres and lodge in cracks, insulation, cable trays and other concealed spaces where they smoulder undetected for hours before igniting. The permit system forces a deliberate pre-work pause, requiring both the operator and the fire watch person to confirm every control is in place before the first arc is struck or the first cut is made. MapTrack enables teams to manage hot work permits digitally with electronic sign-on, location-tagged photo evidence and automated fire watch timers, giving supervisors real-time visibility of every active permit across all sites.

Learn more about compliance and inspections in MapTrack.

Benefits of using this hot work permit template

Fire risk reduction: the structured pre-work checklist ensures combustibles are cleared within the required radius, fire blankets are deployed and fire-fighting equipment is positioned before work begins.
Regulatory compliance: a completed permit demonstrates that the PCBU has met their WHS obligations for managing fire risk associated with hot work, satisfying regulator and insurer expectations.
Clear accountability: the permit records who authorised the work, who is performing it and who is on fire watch, creating a defensible chain of responsibility.
Post-work fire watch: the built-in fire watch section ensures the area is monitored for a minimum of 30 minutes after the last spark, catching delayed ignition before it becomes an uncontrolled fire.
Atmospheric safety: the gas testing section prompts LEL testing in areas where flammable vapours may be present, preventing ignition of explosive atmospheres.
Consistent process: a standard template ensures the same safety checks are applied across all sites, shifts and workers, regardless of the supervisor on duty.

Benefits of digitising forms in MapTrack

When you move your permits from paper to MapTrack, you get:

Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
Automatically get alerts when faults are identified.
Link every form digitally as a PDF to the relevant asset, location or person.
Receive a digital PDF copy with every submission to your email.
Ability to share forms digitally.
Build conditional logic (show or hide questions based on answers).
Take pictures or attach photos. Not possible with a paper-based form.
Electronic signatures.
Edit forms later without reprinting.
Restrict permissions (who can view, complete or approve).
Build forms with AI (describe what you need and MapTrack suggests the form).
Escalate critical hazards instantly to safety managers via push notification.
Maintain an auditable safety register that satisfies WHS regulator requests.
Correlate incident trends across sites with built-in safety analytics.

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What to include in a hot work permit template

This hot work permit template covers 9 key areas:

Permit details: unique permit number, date, valid-from and valid-to times, site, location and project.
Hot work description: type of work (welding, cutting, grinding, brazing, soldering, other), specific location within the site, equipment to be used and estimated duration.
Personnel: hot work operator name, fire watch person name, permit issuer name.
Pre-work area inspection (P/F/N/A): area inspected within 11 m radius, combustibles removed or covered with fire-resistant blankets, floor swept clean, wall and floor openings sealed, flammable liquids and gases removed or isolated, sprinkler system operational (if applicable), fire extinguisher within 3 m, ventilation adequate, atmospheric testing completed (LEL below 5%), welding screens or barriers in place, hot work signage displayed, adjacent areas above and below checked.
Fire-fighting equipment check: fire extinguisher type and expiry, fire blanket available, fire hose accessible (if fitted).
Atmospheric testing: LEL reading, O2 reading, instrument ID and calibration date.
Permit authorisation: permit issuer signature, hot work operator signature, fire watch person signature, date and time.
Post-work fire watch record: fire watch start time, end time (minimum 30 minutes), fire watch person confirmation signature.
Permit close-out: area re-inspected for hot spots, permit cancelled, close-out signature, date and time.

How to use this hot work permit template

Complete the permit header: assign a unique permit number, record the date, valid-from and valid-to times, site, specific location and project name.: The permit number provides traceability across the site permit register. Record the exact start and finish times the permit is valid for. The permit expires at the stated time and a new permit must be issued if work continues beyond that window or if the scope, location or personnel change.
Describe the hot work to be performed, including the type, location, equipment and estimated duration, and record the operator and fire watch person names.: Be specific about the work type and the exact location so that anyone reading the permit can identify where the work is happening. Name the hot work operator and the fire watch person. The fire watch person must remain in the area during the work and for the full post-work monitoring period.
Inspect the work area within an 11 m radius. Clear or protect all combustible materials, seal openings, and position fire-fighting equipment within 3 m of the work.: Walk the full 11 metre radius around the planned work location. Remove all combustible materials, or cover them with fire-resistant blankets where removal is not practical. Sweep the floor clean of dust and debris. Seal any gaps in walls, floors and ceiling penetrations that could allow sparks to travel to adjacent areas. Position at least one serviceable fire extinguisher of the correct type within 3 metres of the work. Check the areas directly above and below the work location.
Conduct atmospheric testing where flammable vapours may be present. Record LEL and O2 readings on the permit.: If the work area is in or near a space that may contain flammable vapours (fuel storage, chemical plants, confined spaces), use a calibrated gas detector to measure the lower explosive limit (LEL) and oxygen (O2) levels. The LEL must be below 5% before hot work is authorised. Record the readings, the instrument serial number and its calibration date on the permit.
Work through the pre-work checklist and mark each item as Pass, Fail or N/A. Do not issue the permit if any critical item fails.: Complete every checklist item systematically. A Fail on any critical item means the condition has not been met and must be rectified before the permit is issued. Record specific notes for any failed item to guide rectification. The overall result must reflect the worst individual outcome.
Obtain signatures from the permit issuer, hot work operator and fire watch person to authorise the work.: Each signature confirms the signatory has verified the controls relevant to their role. The permit issuer confirms all pre-work conditions have been met. The operator confirms they understand the scope and controls. The fire watch person confirms they will remain in the area with fire-fighting equipment for the duration of the work and the post-work monitoring period.
After work is complete, conduct post-work fire watch for a minimum of 30 minutes. Record the start and end times on the permit.: The fire watch person remains in the area with a fire extinguisher for at least 30 minutes after the last spark or flame. Many site procedures require 60 minutes or longer for higher-risk work. Monitor for smouldering, hot spots, unusual smells or discolouration. Record the fire watch start time and end time on the permit.
Close out the permit: re-inspect the area for hot spots, cancel the permit and sign off.: Walk the 11 metre radius and check all surfaces for residual heat. Use the back of your hand near (not touching) surfaces to detect warmth. Once satisfied there are no hot spots or signs of fire, cancel the permit by drawing a line through it or marking it as closed, record the close-out time and sign off. File the completed permit in the site permit register.

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How often should you complete this permit?

A hot work permit must be completed before every instance of hot work, including welding, cutting, grinding, brazing, soldering or any work producing sparks, open flames or high temperatures. A new permit is required at the start of each day or shift, whenever the scope or location changes, whenever personnel change, and whenever conditions change (e.g. weather, ventilation, introduction of new combustible materials nearby). The permit is valid only for the time period, location and scope stated on the form. If work extends beyond the valid-to time, the permit must be re-issued.

Safe Work Australia's guidance on managing fire and explosion risks recommends that the hot work permit system be audited at least annually. Organisations with frequent hot work should also conduct periodic spot-checks to verify that permit conditions are being followed in the field.

Frequently asked questions

What is a hot work permit and when is one required?: A hot work permit is a formal written authorisation that must be obtained before any work involving open flames, sparks or heat-producing processes such as welding, cutting, grinding, brazing or soldering. It is required on most Australian construction and industrial sites as part of the permit-to-work system under WHS Regulations. The permit ensures the work area has been inspected, combustibles cleared, fire-fighting equipment positioned and a fire watch assigned. A new permit is needed each day or shift, and whenever the scope, location or personnel change.
How long must fire watch continue after hot work?: Fire watch must continue for a minimum of 30 minutes after the last spark or flame produced by the hot work. Many Australian site safety management plans require 60 minutes or longer for higher-risk work or work in areas with concealed combustibles such as insulation, cable trays or wall cavities. The fire watch person must remain in the area with a serviceable fire extinguisher, monitoring for smouldering, hot spots and unusual smells. The hot work permit must not be closed out until the full fire watch period is complete and a final area inspection confirms no signs of fire.
What distance must be cleared of combustibles before hot work?: Under AS 1674.1 and industry best practice, all combustible materials must be removed or protected within an 11 metre radius of the hot work location. This includes timber, paper, cardboard, oil, grease, solvents, gas cylinders, aerosol cans, plastic sheeting and insulation. Materials that cannot be removed must be covered with fire-resistant blankets or welding screens. Floor sweepings, dust and debris must also be cleared. Wall and floor openings within this radius must be sealed to prevent sparks travelling to adjacent areas.
What atmospheric testing is required before hot work?: Atmospheric testing is required before hot work is performed in any area where flammable vapours, gases or dusts may be present. A calibrated gas detector must measure the lower explosive limit (LEL) and confirm it is below 5% before the permit is issued. Oxygen levels should also be verified. Testing is particularly important near fuel storage, chemical processing, tanks, pipelines, confined spaces and drainage systems. If LEL readings rise during work, the hot work must stop immediately and the area must be ventilated and retested before resuming.
Is this hot work permit template free to use?: Yes. Download and use this hot work permit template for free. Open the file in your browser and use Print then Save as PDF. No MapTrack account is required. If you want digital hot work permits with electronic sign-on, GPS-tagged photo evidence, automated fire watch timers and a complete permit register across all your sites, MapTrack can help. Book a demo to see how it works.

Applicable regulatory standards

This template aligns with the following regulations and standards:

AS 1674.1 - Safety in welding, brazing, cutting and allied processes: Fire precautions
NFPA 51B - Standard for Fire Prevention During Welding, Cutting, and Other Hot Work
WHS Regulations 2011 - Chapter 3 Part 3.1 (Managing risks to health and safety)
Safe Work Australia - Code of Practice: Welding processes

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