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HOT WORKS FIRE RISK: WHY INSURERS ASK SO MANY QUESTIONS
What Is Hot Works Fire Risk?
“Hot works” describes processes that create heat, sparks, molten metal or open flame. In metal fabrication and manufacturing, this includes welding (MIG, TIG, MMA/arc), oxy-fuel cutting, plasma cutting, grinding, soldering and brazing. These activities introduce ignition sources into environments where combustibles, dusts, vapours and hidden voids may be present.
Hot works fire risk is one of the main reasons insurers treat welding and cutting trades differently to general manufacturing. A single spark can travel, lodge in insulation or voids, and ignite a fire that develops later (often after the job has finished). The resulting loss can involve major property damage, business interruption and third-party claims.
This page explains why the risk is taken so seriously, the controls insurers expect to see, and how specialist insurance can help protect your business when incidents occur.
Why Fires Start During Welding, Cutting & Grinding
Most hot works fires are not caused by a dramatic explosion. They start with small ignition sources and poor conditions: sparks entering concealed spaces, heat transfer through metalwork, or combustibles left too close to the work area.
- Sparks and molten particles travel further than expected
- Heat transfers through steelwork into concealed combustibles
- Insulation, cladding and voids hide ignition points
- Dusts, vapours and residues create flammable atmospheres
- Poor housekeeping leaves packaging, rags or waste near hot works
- Inadequate fire watch after work is completed
- Incorrect isolation of gas lines or fuel sources
- Failure to follow permit-to-work requirements
Controls Insurers Expect for Hot Works
Insurers and clients often require evidence of practical, documented controls. The better your controls, the more likely you are to secure competitive terms and avoid exclusions. These controls also reduce the chance of an incident.
Hot Works Permits & Fire Watch
- Use of permit-to-work for all hot works outside designated safe areas
- Defined fire watch during works and for a set period afterwards
- Removal or protection of combustibles within the work radius
- Use of fire blankets, screens and spark containment
- Suitable extinguishers available and operatives trained to use them
Workshop & Site Risk Management
- Housekeeping: waste control, clear floors, removal of rags/packaging
- Control of flammables: correct storage of paints, solvents and gases
- Ventilation/extraction to reduce fume and vapour build-up
- Isolation of fuel lines/gas services where applicable
- Documented RAMS (risk assessments and method statements)
How Hot Works Fire Risk Affects Your Insurance
Insurers often apply special terms for welding and hot works. If hot works are not declared and accepted, you may find: exclusions on welding, higher excesses, restrictive conditions, or difficulties obtaining cover.
The best approach is to disclose your activities clearly and demonstrate your controls. This reduces the chance of “coverage disputes” at claim stage and improves underwriting confidence.
Common Policy Features / Conditions
- Hot works warranties or conditions (permits, extinguishers, fire watch)
- Higher policy excess for fire-related claims
- Restrictions on work in certain environments (e.g., high-hazard premises)
- Requirements for training and competency records
- Specific security standards for premises and tools
What Cover Can Respond After a Fire?
- Public Liability – third-party property damage/injury claims (where hot works are declared and accepted)
- Property Insurance – damage to your own workshop/factory (if insured)
- Business Interruption – loss of income following insured damage
- Tools/Equipment – replacement of damaged welding kit (where included)
- Environmental Liability – potential clean-up costs from contaminated runoff (wording dependent)
Why Choose Insure24
Welding and hot works are frequently misunderstood in “off the shelf” insurance. We help fabrication businesses arrange cover that correctly reflects hot works activities and reduces gaps caused by unclear descriptions or hidden exclusions.
- Specialist advice for welding and fabrication operations
- Access to insurers who can accept hot works risks
- Support with risk presentation and controls
- Combined cover options (liability + property + tools)
- Clear documentation and claims support
FREQUENTLY ASKED QUESTIONS
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What activities are classed as hot works?
Hot works usually includes welding (MIG/TIG/arc), oxy-fuel and plasma cutting, grinding, brazing and any activity producing heat, sparks or open flame.
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Why do hot works fires sometimes start after the job finishes?
Sparks or heat can enter concealed voids, insulation or cavities and smoulder before igniting later. This is why fire watch procedures are critical after hot works are completed.
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Will my public liability cover hot works fire damage?
Potentially, but only if hot works are declared and accepted by the insurer and you comply with policy conditions. Many generic policies exclude or restrict welding and hot works unless specifically agreed.
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Do I need a hot works permit in my own workshop?
Many businesses operate designated hot works areas and still apply internal permit-style controls. Insurers focus on practical controls such as housekeeping, separation of combustibles, extinguishers and documented procedures.
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What controls help reduce premiums for welding risks?
Strong housekeeping, clear hot works procedures, trained operatives, suitable extinguishers, fire watch, correct storage of flammables, good extraction/ventilation and documented RAMS can all improve underwriting outcomes.