In this episode we're picking the top hot work safety risks that we've encountered over our careers that can create the perfect storm for a fire event during hot work activities, with luck playing a major role in why some buildings are still standing. Give this episode a listen, and see if your facility has any of these hot work process management risks:

“Top Failures in Hot Work Safety – Not Your Typical Toolbox Talk”

🔥 Overview:

In episode of Safe, Efficient, Profitable, hosts Joe and Jen of Allen Safety go beyond the basics of hot work training to uncover the top failures in hot work safety programs—the kind that can literally burn your facility down if left unaddressed. Forget the standard "check your extinguisher" talk—this is a real-world, experience-driven deep dive based on years of safety audits, incidents, and lessons learned on the ground.

This episode is a must-listen for safety professionals, plant managers, contractors, and fire watch personnel looking to prevent catastrophic fire risks during welding, cutting, and grinding operations.

🔥 Key Points Covered:

Fire Watch Confusion

Many Fire Watch personnel don’t understand where to stand, how long to stay, or how to follow the work if it moves.

Most training doesn’t address real-world logistics or site-specific protocols.

Undefined Hot Work Areas

Critical visibility issues arise when Fire Watch personnel are nowhere near the hot work.

Real examples include watching welding work 50+ feet away or in confined spaces—ineffective and dangerous.

Incomplete Permit Processes

Hot work permits are often pre-filled, not site-specific, or treated as blanket 8-hour approvals.

There’s a lack of accountability around evaluating new locations, travel paths, and potential hazards as work progresses.

Distance & Multiple Weld Zones

Welding that spans 200+ feet of conveyor systems or fencing requires multiple permits and Fire Watch assignments, not just one.

Permits need to consider clearance areas (35 feet around each weld), extinguisher placement, and actual work duration.

Shift Transitions & Breakdowns in Fire Watch Coverage

Contractor Liability Gaps

Confusion over who is liable—contractor vs. host site—especially when personnel change mid-project.

This opens the door for unapproved hand-offs, missed hazards, and untracked accountability.

The Root of It All: Lack of Planning

Most issues stem from a lack of project planning.

Pre-job assessments are rushed or overlooked, especially for multi-employer worksites.

Without the right number and quality of trained personnel, hazards slip through the cracks.

🔍 SEO Keywords & Phrases:

Hot work safety failures
Fire watch best practices
Welding permit compliance
Preventing fires during hot work
Hot work hazard assessment
Allen Safety podcast
Industrial fire prevention
Safety planning for contractors
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Real-world fire watch training

💡 Final Takeaway:
“Hot work safety is about way more than checking extinguishers—it’s about people, planning, positioning, and responsibility.”
If your team is unclear on any of those, it’s time to revisit your program.

🎯 For More Support:

Visit AllenSafety.com for onsite training and safety services.

Explore AllenSafetyCoaching.com for virtual coaching, resources, and free email support.

This episode is intended for educational purposes. Solutions offered are not designed to take the place of an attorney or medical professional, and should not be taken as legal or medical advice. It is recommended that viewers consult a safety consultant, medical provider or an occupational safety legal team as applicable to help navigate their specific

Working at Farms, feed lots, and feed mills. They are absolutely an "if you know you know" type work place, which can create some risks if that person becomes a new hire! In this episode, Joe and Jen skip right over some of the more "traditional" Hazards and move right to things that make you go "huh."🤔 This was a fun one to make- we hope you guys enjoy it! Full episode summary below:

Key Points:
1. Biosecurity & Industrial Hygiene
Farm safety starts before driving onto the property—biosecurity measures require washing vehicles, showering in/showering out, wearing designated clothing, and sanitizing tools.

2. Safety Challenges in Farming Environments
Hot Work (e.g., welding, grinding) is unique on farms due to open spaces, uncontrollable factors like ventilation, and farm managers (rather than safety officers) issuing permits.
Training is often unrealistic—safety training (e.g., first aid/CPR) is typically taught in an office setting but must be applied in unpredictable farm conditions (e.g., near animals, in extreme weather, in remote locations).
Lockout/Tagout (LOTO) issues—farms have stored energy hazards (e.g., augers retaining power), which may not be adequately addressed through standard LOTO procedures.
3. Equipment-Specific Hazards
Leaf blowers pose a unique risk—they can catch long hair or loose clothing, an overlooked danger due to differences in PPE use on farms versus industrial sites.
Tractors and equipment can vary significantly—workers may have to operate multiple brands and models, requiring flexible and adaptable training.
Outdoor work adds risks—workers may be alone, exposed to extreme weather, or using outdated PPE/equipment.
4. Routine Tasks Can Be High-Risk
Pest control, handling chemicals, and general hygiene practices pose hidden risks—workers may unintentionally contaminate themselves (e.g., scratching their nose while wearing contaminated gloves).
People that have been at the faciality for many years may be accustomed to certain risks—they may develop unsafe habits over time due to familiarity with their tasks and environment.
5. Emergency Preparedness & Response
Fires, tornadoes, and medical emergencies require special planning since farms are often rural and lack immediate emergency response access.
During emergencies, animals must also be managed—creating additional logistical and safety concerns.
Returning to normal operations post-emergency is often overlooked—many farm safety plans lack a structured approach for resuming work safely.
6. Housekeeping & Sanitation Differences
Housekeeping expectations vary by farm type—some areas (e.g., mills) must be cobweb-free, while feedlots prioritize biosecurity.
Inspection routines should be tailored to each location—ensuring electrical panels, PPE, and equipment cleanliness meet site-specific safety standards.
Contractors & maintenance personnel need clear guidance—a well-planned inspection and task list can prevent biosecurity risks when bringing in external workers.
7. The Need for Better Training & Documentation
Farm safety programs should be location-specific, as no two farms operate the same way. The training should be accessible at the farm- and not just at the main office.

For more information, they direct listeners to AllenSafetyCoaching.com or Allen-Safety.com websites for training, evaluations, and audits tailored to farm safety.

This video is intended for educational purposes. Solutions offered are not designed to take the place of an attorney or medical professional, and should not be taken as legal or medical advice. It is recommended that viewers consult a safety consultant, medical provider or an occupational safety legal team as applicable to help navigate their specific circumstances.

We've all seen the boiler-plate electrical safe work practice & electrical awareness training. This isn't that. In this episode, we're challenging your program, what's covered in training, who gets training, and even your routine safety inspections to give you a fresh way to view electrical safety at your facility. If this helped you, please support us by liking and sharing the episode and thank you for listening! Full episode description below:

This episode dives deep into common electrical hazards overlooked during inspections and audits, highlighting critical gaps in personal protective equipment (PPE), voltmeter use, and general facility maintenance. By emphasizing real-world scenarios, the hosts discuss how to strengthen electrical safety programs through collaborative efforts with electricians, maintenance and utilities departments. The episode is packed with actionable advice and key insights for improving electrical safety.

Key Points:
1. Personal Protective Equipment (PPE) Gaps:
Improper use of arc flash clothing and untrained staff wearing non-rated clothing.
Specific Concerns: Workers rolling up sleeves, incorrectly washing arc flash clothing, and mismatches in PPE due to gaps in supply and policy oversight.

2. Voltmeter Training and Misuse:
Untrained or insufficiently trained personnel using voltmeters improperly, leading to dangerous arcing incidents.
Training Gaps: Inconsistent policies on who should use voltmeters and when they should check for power.

3. Environmental Hazards in Electrical Rooms:
Water and Corrosion: MCC rooms often have water ingress issues due to poor drainage, condensation, or wet cleanup areas.
Impact: Water and chemical exposure can cause equipment failures and create shock hazards.

4. Dust and Explosive Risks:
Dust accumulation near electrical equipment (e.g., mills, conveyor systems) increases fire risk from ignition sources such as motors, bearings etc.

5. Safety Program Ownership:
Many safety programs are unclear and too vague or overly complex, with safety teams managing areas outside their expertise resulting in programs outlining processes the facility does not actually do.

6. Importance of Accurate Labeling:
Incorrect labeling of electrical panels and disconnects can lead to dangerous situations where hazard levels are misunderstood.

7. Collaborative Risk Assessments:
Engage electricians, maintenance staff, and safety teams in collaborative reviews and risk assessments tailored to specific locations.

Keywords:
Electrical safety hazards
PPE gaps in electrical work
Voltmeter safety training
Lockout/tagout electrical safety
Arc flash protection
MCC room maintenance
Electrical hazard inspections
Housekeeping for electrical safety
Dust explosion prevention
Industrial electrical safety program

This video is intended for educational purposes. Solutions offered are not designed to take the place of an attorney or medical professional, and should not be taken as legal or medical advice. It is recommended that viewers consult a safety consultant, medical provider or an occupational safety legal team as applicable to help navigate their specific circumstances.

Specific job tasks shown are being completed by trained professionals, and should not be attempted without proper training and equipment under the supervision of a professional. Viewer discretion is advised.