ES&H Manual



6122 Hot Work (i.e. Welding, Cutting, Brazing, and Grinding) Safety Program



NOTE: Jefferson Lab has determined that hot work (e.g. welding, brazing, or spark producing grinding or cutting) is considered to be an unmitigated Risk Code >2 and requires an approved work control document (Operational Safety Procedure (OSP), and/or Hot Work Permit) prior to the commencement of operations.


1.0             Purpose


Hot work (e.g. welding, brazing, or spark producing grinding or cutting) is a common part of Jefferson Lab’s fabrication and construction activities. Because of the high temperatures involved and the potential for fire and serious personal injury, care is taken to ensure that work is performed safely. This hot work safety program has been developed to document Jefferson Lab’s minimum safety requirements for this type of work. 

This program satisfies applicable federal, state, and local requirements as outlined in ES&H Manual Chapter 2410 Appendix T1 Hazard Issues List. 

A copy of the “American National Standards Institute (ANSI) document Z49.1, Safety in Welding, Cutting, and Allied Processes” is available through the Environmental, Safety, Health, and Quality (ESH&Q) Department, contact the Technical Point-of-Contact for this document.


2.0             Scope


This chapter and its associated appendices apply to all hot work performed at Jefferson Lab. The two areas where hot work is permitted onsite are outlined below.

2.1              Permanent (i.e. a weld shop) – established by an Operational Safety Procedure (OSP). See ES&H Manual Chapter 3310 Operational Safety Procedure Program for more information.


The following special welding operations require the following considerations over and above that of the permanent welding area:

·         Electron Beam Welding (used in the Test Lab to fabricate super conducting RF cavities) – Requires a separate relevant OSP. 

·         Laser Beam Welding – Requires a separate relevant Laser Operational Safety Procedure (LOSP). 

·         Thoriated Tungsten Electrodes – When sharpening or grinding Thoriated Tungsten Electrodes use appropriate enclosed grinder to capture grinding dust. Contact the Radiation Control Department when disposal of the dust is required. 

2.2              Temporary – requires a Hot Work Permit outlining the specific safeguards to be used. See ES&H Manual Chapter 6900 Appendix T1 Fire Protection:  Hot Work Permit for more information.


Table 1: Required Hot Work Safety Training by Job Classification

Training Course

Qualified Hot Work Operator

Qualified Welder

Fire Watch

Fire Safety Training





Welder Safety





Operate or Repair Pressure or Vacuum Systems





Visual Acuity For Welders





Shielded Metal Arc Welding (SMAW)





for Gas Tungsten Arc Welding (GTAW)





Oxy Fuel Welding/Brazing (OXY/FUEL)





Flux Core Arc Welding (FCAW)





Gas Metal Arc Welding (GMAW)





Automatic Gas Tungsten Arc Welding (GTAW-A)





* Per ES&H Manual Chapter  6800 Appendix T1 Medical Monitoring

** As Appropriate. Contact the QA/CI Senior Technical Specialist for Certification Qualification requirements


3.0             Responsibilities and Qualifications

NOTE:           Management authority may be delegated to a task qualified Jefferson Lab employee at the discretion of the responsible manager.


3.1              Qualified Hot Work Operator:

·         Complete and maintain appropriate training, certification, and medical monitoring including SAF 108 Fire Safety Training. 

·         Have supervisor approval prior to commencement of hot work.

·         Follow all guidance in this chapter and any authorizing Work Control Document (including Hot Work Permit) as applicable.

·         Inspect PPE before and after use. Dispose of damaged items appropriately.

·         Wear appropriate PPE while working.

·         Frequently change or alternate gloves and other protective clothing to avoid perspiration accumulation.

·         Prior to commencement of work, ensure equipment complies with inspection requirements. See ES&H Manual Chapter 6122 Appendix T3 Inspection of Hot Work Equipment.

·         Request an equipment/area hazard evaluation from Industrial Hygiene if you have concerns regarding area hazards or postings.


3.1.1        Qualified Welder also:

·         Certified in accordance with ASME code and AWS code. Contact the QA/CI Senior Technical Specialist (x5859) for certification qualification requirements.


3.2              Fire Watch:

·         Abide by the responsibilities outlined within ES&H Manual Chapter 6900 Appendix T1 Fire Protection:  Hot Work Permit. 

·         Complete and maintain SAF 108 Fire Safety Training.


3.3              Supervisor/Subcontracting Officer’s Technical Representative (SOTR)/Sponsor

·         Ensure that the Qualified Hot Work Operator assigned to hot work activities is appropriately trained and qualified to perform the work. See the updated list of certifications for welding operations.

·         Establish appropriately configured hot work area(s). Include requirements outlined within this chapter and appropriate work control documents (e.g.: OSP or Hot Work Permit)

·         Ensure only approved equipment and PPE is available and used in hot work areas.

·         Ensure warnings are posted in areas under your authority in accordance with requirements.

·         Ensure cleaning and maintenance of ventilation systems is scheduled in accordance with hazard evaluation requirements.


3.3.1        SOTRs Also:

·         Advised subcontractors of Jefferson Lab’s requirements regarding hot work operations.


3.4              Equipment Owner

·         Ensure equipment is inspected annually (at a minimum) and maintained in accordance with the Operator’s Manual and Jefferson Lab requirements.


3.5              Industrial Hygiene

·         Perform area hazard evaluation.


3.6              QA/CI Senior Technical Specialist

·         Inspect welding operations at Jefferson Lab.

·         Certify and document all Jefferson Lab Qualified Welders in accordance with ASME code and AWS code. 

·         Verify that annual welding equipment inspections are performed.


4.0             Expectations


4.1              Hot Work Station Set-up

There are a number of inherent hazards associated with hot work operations.  Appropriate work station set-up is one method to avoid hazards. ES&H Manual Chapter 6122 Appendix T1 Hot Work Station Set-Up and Safe Operating Procedures (includes Oxygen/Fuel Safety) outlines Jefferson Lab’s minimum requirements for station set-up and equipment maintenance.


4.2              Personal Protective Equipment

Jefferson Lab recognizes that hot work exposes workers to certain recognized hazard issues, some of which can be mitigated through the use of appropriate personal protective equipment (PPE). ES&H Manual Chapter 6122 Appendix T2 Hot Work Personal Protective Equipment (PPE) provides information on how to: determine the appropriate PPE, and obtain it.


4.3              Equipment Inspections

Annual inspections of welding and cutting equipment are required to ensure it is kept in good operating condition. ES&H Manual Chapter 6122 Appendix T3 Inspection of Welding and Cutting Equipment outlines the responsibilities and process steps established by Jefferson Lab to ensure compliance with this requirement.


4.4              Posting Requirements

Jefferson Lab recognizes that hot work is inherently dangerous. It is therefore required that designated areas and associated equipment be labeled to provide warning of potential hazards.  ES&H Manual Chapter 6122 Appendix T4 Hot Work Area Posting Requirements defines Jefferson Lab’s labeling and posting requirements; and how to update, repair, and maintain these labels. 


4.5              Ventilation/Respiratory Requirements

Respiratory hazards are often associated with hot work operations (in particular welding). In order to control exposure to harmful gases/fumes, local or general exhaust ventilation is required during welding operations. ES&H Manual Chapter 6122 Appendix T5 Hot Work Ventilation/Respiratory Requirements provides Jefferson Lab’s minimal ventilation requirements. Currently T4


4.6              Communicating Quality Standard Requirements

Quality standards for welding and brazing work at Jefferson Lab are provided in the “Welding and Brazing Program Supplement.”  This document provides the minimum requirements for the following activities in relation to weld(s) and braze(s):

·         Design

·         Inspection and examination

·         Procedure specification and qualification

·         Material control

·         Performance qualification


5.0             Revision History


Periodic Review – 03/25/16 – No changes per TPOC

Revision 1.1 – 05/20/14 – Added Required Safety Training Table.

            Revision 1.0 – 04/11/11 – Updated to reflect current laboratory operations.











ESH&Q Division

Jenord Alston





This document is controlled as an on line file.  It may be printed but the print copy is not a controlled document.  It is the user’s responsibility to ensure that the document is the same revision as the current on line file.  This copy was printed on 2/21/2020.