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WELDING & HOT WORKS INSURANCE THAT HELPS YOU WORK WITH CONFIDENCE
Why Welding & Hot Works Insurance Matters
Welding and hot works are among the highest-risk activities in metal fabrication and engineering. Whether you are operating a fabrication workshop, travelling to client sites as a mobile welder, or welding as part of structural steel, pipework, maintenance or installation projects, you face a unique combination of fire hazards, injury exposures and contractual liabilities.
“Hot works” commonly includes welding (MIG, TIG, MMA/arc), cutting (oxy-fuel, plasma), grinding, soldering, brazing and any process that produces heat, sparks, molten metal or an ignition source. These operations can trigger strict insurer requirements and, in some cases, outright exclusions if the activity is not declared properly.
Insure24 arranges specialist welding & hot works fabrication insurance that’s designed for real-world work conditions: jobs in workshops, on construction sites, inside industrial units, on plant and machinery, within confined spaces, and on high-value client property. We help you secure cover that aligns with your trade, your contracts and your risk controls, so you can get on with the job.
Core Welding & Hot Works Cover
Your policy should be built around the exposures that matter most: third-party injury and property damage, hot works-related fire risk, employee injuries, and the tools/equipment you rely on. We structure cover so it makes sense for fabrication businesses (not generic “tradesman” wording), and we make sure your hot works activities are described clearly for insurer acceptance.
- Public Liability – covers your legal liability for injury to third parties or damage to their property, including incidents arising from sparks, heat transfer, falling steel, or site activities.
- Products Liability – covers claims caused by defective fabricated items after handover (e.g., a weld failure leading to damage, injury, or downstream loss).
- Employers’ Liability – UK mandatory cover (if you employ anyone) for injuries/illnesses such as burns, eye injuries, fume inhalation or manual handling claims.
- Tools & Equipment – protection for welders, torches, regulators, grinders, generators, leads, PPE, and specialist kit against theft, loss and accidental damage.
- Contract Works – covers fabrication and installation work in progress, including materials on site and partially completed structures.
- Business Interruption – helps protect turnover and fixed costs following insured damage to premises or equipment that stops work.
- Property / Workshop – for your premises, contents, stock (steel, plate, sections), and workshop equipment such as compressors and extraction systems.
- Optional Professional Indemnity – for design, specification and advice exposures (e.g., tolerances, load-bearing assumptions, or fabrication drawings).
Common Welding & Hot Works Risks
Welding claims don’t only come from dramatic incidents. Many losses start with small events: a few sparks traveling further than expected, a heat-affected zone weakening a component, a grinder disc shattering, or fumes building up in a poorly ventilated area. A robust insurance policy should anticipate these realities.
- Fire caused by sparks, slag or heat transfer to combustible materials
- Damage to client premises during on-site welding, cutting or grinding
- Injury to third parties from hot debris, falling metal or restricted access areas
- Weld failure, cracking or distortion leading to rework, damage or injury
- Explosion risk linked to gases, vapours, fuel lines or poor isolation
- Fume and particulate exposure allegations (short-term and long-term health claims)
- Theft of tools from vans, sites, containers or workshops
- Contractual disputes and delay claims after defects or non-conformance
- Damage to plant/machinery you are working on (burn-through, warping, misalignment)
Why Choose Insure24
Welding and hot works require specialist underwriting. We don’t try to force your trade into a generic “builders” or “handyman” policy wording. Instead, we present your business to insurers in a way that makes sense: clear descriptions of processes, typical job environments, your controls and your experience. This improves acceptance, reduces surprises at claim stage, and helps keep premiums competitive.
- Specialist guidance – advice from brokers familiar with fabrication and hot works exposures.
- Hot works-friendly markets – access to insurers that can accept welding, cutting and grinding (subject to controls).
- Contract-ready cover – limits and extensions aligned to principal contractor and client requirements.
- Fast turnaround – quick quotations, documentation and certificate provision where possible.
- Claims support – practical help if something goes wrong, including evidence gathering and insurer liaison.
- Flexible options – annual policies, tailored limits, and optional add-ons for tools, works and plant.
How to Get Welding & Hot Works Insurance
Getting the right cover is about more than price. Insurers need to understand what you do, where you do it, and what safety controls you have in place. A well-presented risk can unlock better terms. The steps below mirror our usual process and help ensure your policy is correctly arranged from day one.
- 1. Describe your work – welding types (MIG/TIG/ARC), cutting methods, typical materials (steel, aluminium, stainless), and whether you work in a workshop, on sites, or both.
- 2. Confirm hot works controls – permits, fire watch, extinguishers, spark containment, isolation of services, and housekeeping standards.
- 3. Choose your limits – public/products liability limits, employers’ liability, tool sums insured, and any contract works/property values.
- 4. Add specialist extensions – hired-in plant, professional indemnity, bona fide subcontractor cover, or cover for work on high-risk premises.
- 5. Purchase & activate – once arranged, you’ll receive your documentation and certificates (including for site access where required).
Welding Insurance for Different Types of Fabrication Work
Welding risks vary widely depending on the environment and the nature of the finished product. A fabrication workshop producing gates and railings has different exposures to a mobile welder repairing plant on a construction site, and different again to a pipe welder working on industrial services. We tailor cover so it matches how you actually trade.
Workshop-Based Metal Fabrication
- Premises and contents protection for benches, extraction, compressors and workshop assets
- Stock cover for steel sections, plates, fasteners, consumables and customer property (where applicable)
- Products liability for fabricated items after installation
- Fire risk from hot works, cutting and grinding in production areas
- Business interruption if a fire, flood or theft halts operations
Mobile / On-Site Welding & Hot Works
- Public liability aligned to principal contractor requirements
- Tools in transit and theft cover (vans, sites, locked compounds)
- Contract works for jobs in progress and materials on site
- Cover for work at client premises (subject to underwriting and controls)
- Optional hired-in plant and specialist equipment extensions
Structural Steel & Construction Welding
- High-limit public liability and contract-ready documentation
- Defect and rework risk positioning (products/contract works approach)
- Site safety controls and hot works permit procedures
- Optional professional indemnity if you advise on design/spec
- Extensions for bona fide subcontractors where relevant
Industrial Maintenance & Plant Repairs
- Work on or near high-value plant and machinery (risk presentation is key)
- Hot works around lubricants, fuel systems, dusts and confined spaces
- Support for risk assessments, method statements and client requirements
- Tools, equipment and business interruption options
- Potential need for higher excesses/conditions depending on site risk
Understanding Welding & Hot Works Exposures in Detail
Welding is not a single risk; it is a risk profile made up of heat, ignition sources, electricity, compressed gases, manual handling, working at height, and high-value third-party environments. Insurers typically focus on (1) the probability of a fire or major loss, and (2) the potential severity if it happens. Your aim is to demonstrate competence and controls: trained operatives, disciplined housekeeping, and a clear method statement approach.
Many welding claims arise from “secondary ignition”: sparks or molten particles fall into voids, behind cladding, into insulation, or near combustible materials. The fire may not be visible immediately and can develop later. This is why clients often insist on hot works permits, isolation of combustibles, the use of fire blankets, and a defined fire watch period. Insurance is crucial because even with excellent controls, the financial consequences of a property damage claim can be catastrophic.
Beyond fire, liability can arise from weld quality and compliance. If a welded connection fails, it can damage property, injure a third party, or cause a chain reaction (for example, a failed bracket leading to a fall of equipment). Even where there is no injury, clients may pursue recovery for rework, delays and access costs. Insurance does not replace good quality management, but it provides critical financial resilience when a claim escalates.
Finally, tools and equipment are a major operational dependency. A stolen welder or generator can stop jobs immediately; a damaged torch or regulator can create safety issues; lost PPE can prevent site access. A policy structured with appropriate tools cover and realistic sums insured can keep you trading through disruptions.
Fire & Property Damage Risk
Fire is the defining exposure for welding and hot works. In workshops, the risk is linked to layout, ventilation, extraction, storage of flammables, and housekeeping. On sites, the risk expands: you may be working near combustible building materials, foam insulation, dusts, vapours, timber, packaging, or hidden voids.
Good underwriting presentation includes: clear separation of hot works areas, availability of extinguishers, use of fire blankets, isolation of services, and a documented permit-to-work approach. Where you can evidence these controls, insurers are more likely to provide broader terms and better pricing.
- Sparks, slag and molten metal ignition sources
- Heat transfer through steelwork into hidden combustibles
- Welding near fuel lines, lubricants or gas systems
- Confined spaces and reduced ventilation
Liability & Defect Risk
Liability exposures include both immediate incidents (injury/damage during works) and delayed issues (defective products after handover). For fabricators, the “products” element can be particularly important because fabricated items can remain in use for years. The right cover is about ensuring your policy responds to third-party injury and property damage allegations linked to your fabricated items, while understanding where contractual rework costs may sit outside standard liability.
If you provide any advice on design, tolerances, load paths, or drawing interpretation, you may also need professional indemnity. This is especially relevant when you work to client drawings but you are asked to “make it work” on site.
- Third-party injury arising from site works
- Damage to client property during welding/cutting
- Products liability for fabricated items post-handover
- Optional PI for design/specification exposures
People, Fumes & Workplace Injury
Welding environments can involve burns, eye injuries, electric shock, noise exposure and respiratory hazards. Employers’ liability is legally required if you employ staff, and it is a key part of protecting your business if someone alleges injury or illness. Insurers also look for evidence of training, PPE and safe systems of work.
- Burns, arc eye and hand injuries
- Fume exposure and respiratory allegations
- Manual handling injuries moving steel and equipment
- Working at height and access equipment risks
Tools, Equipment & Business Continuity
For many welding businesses, your equipment is your livelihood. If your tools are stolen or damaged, you lose days, sometimes weeks. A properly structured policy can include tools cover (including items left in vehicles where permitted by policy terms), hired-in plant extensions, and business interruption options if your premises is damaged.
- Tool theft from vans and sites
- Accidental damage to welders and generators
- Replacement hire costs to keep jobs moving
- Interruption cover following insured loss
The Real Cost of a Welding or Hot Works Incident
A hot works incident can become expensive quickly because it often involves multiple categories of loss: property damage, third-party claims, legal costs, project delays and reputational impact. Even a “small” fire can require smoke remediation, replacement of materials, and temporary shutdowns. If you are working on a client site, you may also face additional scrutiny around permits, supervision and method statements.
The aim of insurance is to protect your balance sheet from worst-case outcomes while supporting day-to-day resilience. Most welding businesses are not just buying a policy; they are buying the ability to continue trading after an unexpected event.
Direct Losses
- Legal defence costs and settlement payments for third-party injury/damage
- Fire damage repairs and reinstatement costs
- Replacement of stolen or damaged tools and equipment
- Emergency response costs where covered by policy terms
- Investigation and expert reporting costs in complex liability claims
Indirect & Hidden Costs
- Project delays and knock-on disruption to cashflow
- Lost income while equipment is replaced or premises restored
- Client relationship strain and re-tendering risks
- Increased future insurance premiums after a major claim
- Management time dealing with incident response and documentation
Practical Example
Imagine a mobile welder is carrying out repairs inside an industrial unit. Despite a permit-to-work, a spark enters a void behind cladding, igniting insulation. The fire develops after work finishes. The resulting claim may include the cost of reinstatement, loss of use of the building, emergency response, and a legal claim alleging negligence. A policy with correctly declared hot works and appropriate liability limits is designed to respond to this kind of scenario.
Assess Your Hot Works Risk Profile
Insurers price welding and hot works based on hazard (what could happen) and control (how you prevent it). The stronger your controls, the more likely you are to receive broader acceptance. During the quote process we help you clearly present your processes and risk management approach so underwriters can make a confident decision.
Risk Assessment Areas
- Typical job environments (workshop, construction sites, industrial premises)
- Hot works permit-to-work procedures and fire watch time
- Housekeeping, waste control and combustible separation
- Gas storage, cylinder handling and regulator safety
- Ventilation, extraction and fume control
- Training, qualifications and supervision arrangements
- Use of PPE, fire blankets, screens and barriers
- Tool security, van security and site storage arrangements
Key Underwriting Factors
- Turnover split between welding/hot works and non-hot works fabrication
- Type of welding/cutting and typical materials worked on
- Work at height, confined spaces and industrial plant exposure
- Any work on petrochemical sites, refineries or high-hazard environments
- Claims history and lessons learned / improvements implemented
- Contractual terms, liability limits required and scope of responsibility
- Subcontractor usage and labour-only arrangements
- Geographic spread and where your teams typically operate
How Specialist Welding Insurance Helps Real Businesses
The value of a specialist policy becomes clear when a claim happens. Below are typical scenarios that demonstrate why correct disclosure of hot works, realistic limits and the right extensions are essential.
Case Study: Hot Works Fire on a Client Site
Situation: A mobile welder completes a repair job inside a unit. A spark enters a concealed void and ignites insulation after the team leaves.
Impact: Property damage, smoke remediation and business interruption for the client results in a significant third-party claim.
Resolution: With hot works correctly declared and public liability in place, the claim is managed through the insurer with legal support and settlement handling.
Case Study: Defective Fabrication Allegation
Situation: A fabricated bracket fails after installation, damaging equipment. The client alleges poor workmanship.
Impact: The client seeks recovery for damage and associated losses. An engineer’s report is required to assess causation.
Resolution: Products liability responds to third-party property damage allegations, and the claim is investigated with expert support.
Case Study: Tool Theft Stops Work
Situation: Tools are stolen from a locked vehicle overnight, including a welder and generator.
Impact: Work is delayed, and replacement costs are substantial.
Resolution: Tools cover supports replacement, helping the contractor return to work quickly (subject to policy security conditions).
Case Study: Employee Injury
Situation: An employee suffers a burn injury and alleges inadequate PPE provision.
Impact: Employers’ liability claim includes medical costs and compensation.
Resolution: Employers’ liability responds, and documentation of training and PPE helps defend the claim appropriately.
“Our insurer needed hot works declared properly. Insure24 understood our welding risks and got us cover that matched our contracts.”
Operations Manager, Metal Fabrication ContractorPROTECT YOURSELF
- Your legal defence costs and damages you are legally liable to pay to other parties
- Third-party property damage caused by welding sparks, heat transfer or site activities
- Injury claims involving members of the public, clients or other contractors
- Loss or damage to tools, equipment and specialist welding kit
- Business interruption following insured damage to your premises or equipment
Compliance & Regulations
Welding and hot works insurers often expect evidence of robust safety controls. While your insurance policy provides financial protection, strong compliance reduces the chance of an incident and supports better underwriting outcomes. Our quote process can help you articulate the controls you already use, and highlight gaps that are easy to fix.
Key areas commonly relevant to welding and fabrication include:
- Hot Works permits and fire watch procedures
- Risk assessments and method statements (RAMS)
- COSHH assessments for gases, fumes and consumables
- PUWER compliance for equipment and maintenance records
- Training, certification and competency records
- PPE policies (eye protection, gloves, respirators, hearing protection)
- Safe storage and transport of cylinders and flammables
- Workshop housekeeping and combustible control
FREQUENTLY ASKED QUESTIONS
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What counts as “hot works” for insurance?
Hot works generally includes any process that produces heat, sparks or open flame. This can include MIG/TIG/arc welding, oxy-fuel cutting,
plasma cutting, grinding, soldering and brazing. Insurers may define it slightly differently, so it’s important to describe your activities
clearly when arranging cover.
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Do insurers exclude welding automatically?
Many standard liability policies may restrict or exclude hot works unless declared and accepted by the insurer. Specialist welding and fabrication
cover is designed to ensure your welding and cutting activities are properly underwritten and reflected in your policy documentation.
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Does welding insurance cover fire caused by sparks?
Where hot works are correctly declared and accepted, public liability can respond to third-party property damage claims arising from sparks or heat transfer,
subject to the policy terms, conditions and your safety controls. Always ensure your risk management procedures (permits, fire watch, extinguishers) are followed.
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Do I need employers’ liability if I use subcontractors?
If you employ staff, employers’ liability is a legal requirement in the UK. Some labour-only subcontractor arrangements may also create an EL exposure.
If you’re unsure how your team is structured, speak to us and we’ll guide you on the correct approach.
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Can I get cover for on-site welding and industrial premises?
Yes. Cover is commonly available for on-site welding, including construction and industrial locations, subject to underwriting. Insurers may ask about
permits-to-work, fire watch procedures, confined space work, and whether you work in higher-hazard environments such as petrochemical sites.
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Does products liability cover faulty welds?
Products liability is designed to cover your legal liability for third-party injury or property damage caused by your products after handover. It can apply
to defects in fabricated items if they lead to injury or damage. Pure rework costs or “your own work” rectification may not be covered, depending on the scenario
and policy terms.
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How much welding and hot works insurance do I need?
Your required limits depend on your contracts, the types of sites you work on, and the potential severity of a loss. Many contractors require £2m–£10m public
liability, and employers’ liability is commonly £10m. Tools and contract works limits should reflect realistic replacement costs and project values.
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What information do I need to get a quote?
Typically: your turnover and trade description, the percentage of work that is welding/hot works, where you operate (workshop vs site), any high-hazard site work,
details of your safety controls (permits, extinguishers, training), claims history, and the cover limits you need (PL/EL/tools/works/property).