# Gas-Dangerous Zone Plan: Hot Work and Deck Work Rules > What a gas-dangerous zone plan means for chandlers, agents and repair yards: hot work permits, ESD rules, and what to confirm before you quote. URL: https://vesselreach.si/blog/gas-dangerous-zone-plan-hot-work-and-deck-work-rules | Published: 2026-10-23 | Guide | Topic: Segment playbooks (marine services) ## In short A gas-dangerous zone plan defines where flammable cargo vapour may collect on a gas carrier and which work is restricted there, so it decides whether deck work can start, needs a hot work permit, or must wait until tanks are gas-free. Contractors should confirm zone boundaries, gas readings, permit validity, supervision and stop conditions before quoting. ## Key takeaways - A hot work permit is only valid inside the gas-dangerous zone plan, and the more restrictive document applies when the two disagree. - A 2026 study of the June 2025 MT Federal II fire in Batam found permit procedure violations, weak supervision and failed PPE use as causes. - A 2022 Job Safety Analysis at PT Cahaya Baru Shipyard found welding and cutting caused 23.3% of work accidents. - Quote deck work as conditional when the vessel's cargo state and tank inerting are unclear at enquiry stage. - Port agents should add a PDA line for delays caused by restricted deck access during gas cargo operations. ## At a glance - **What: What caused the June 2025 fire on the MT Federal II?** A 2026 study found the fire at PT ASL Shipyard in Batam was caused by violations of safe working procedures on the hot work permit, lack of supervision and failure of personal protective equipment use. ([Journal of Multidisciplinary Education](https://doi.org/10.23960/47rw5f14)) - **Who: Which shipyard activities carry the most accidents?** A 2022 study at PT Cahaya Baru Shipyard found most work accidents occurred in welding and cutting activities, accounting for 23.3% of cases, and recommended standard operating procedures and better PPE use. ([JKIE (Journal Knowledge Industrial Engineering) (Universitas Yudharta Pasuruan)](https://doi.org/10.35891/jkie.v9i2.3287)) - **Where: Where is a jack-up being converted for a gas field?** A 24-year-old jack-up is arriving at an Asian yard for a rig-to-MOPU conversion before it starts work at a gas development in Southeast Asia, according to Offshore Energy. ([Offshore Energy](https://offshore-energy.biz/2026/10/13/2002-built-jack-up-comes-to-asian-yard-for-mopu-conversion-ahead-of-gas-field-deployment)) - **When: When did Qatar's gas shipments stall?** By late August, even limited Qatari gas shipments had all but stopped following a projectile attack on one of its tankers outside the Strait of Hormuz, according to gCaptain. ([gCaptain](https://gcaptain.com/qatar-rewrites-its-gas-playbook-with-old-tankers-and-new-tactics/)) - **Why: Why did European gas prices rise in October 2026?** Hellenic Shipping News reported both major regional benchmarks gained over 3% as hotter-than-expected British inflation and ongoing Persian Gulf energy disruptions heightened concerns over winter fuel adequacy. ([Hellenic Shipping News](https://www.hellenicshippingnews.com/european-gas-rallies-on-persian-gulf-disruption-pressure-hot-uk-inflation-dents/)) - **How: How did researchers assess risk across ship repair activity?** A 2024 study used FMEA to map ship repair work at a cooperative shipyard, recording 26 activities across preparation, docking and post-docking stages and identifying 40 hazard sources. ([International Journal of Marine Engineering Innovation and Research (Sepuluh Nopember Institute of Technology)](https://doi.org/10.12962/j25481479.v9i1.20084)) A gas-dangerous zone plan is the document a gas carrier, terminal or repair yard uses to define where flammable gas may be present and which work is restricted there. For deck contractors, it decides whether your job can start, needs a hot work permit, or cannot be done at all until the ship is gas-free. If you quote deck work, tank cleaning support or steel repairs on an LNG (liquefied natural gas) or LPG carrier, the plan is a commercial document as much as a safety one. It sets the schedule, the supervision and the cost of your job. ## What a gas-dangerous zone actually covers A gas-dangerous zone is any space or deck area where cargo vapour could collect at a concentration that can burn. It usually includes the cargo tank area, manifold region, compressor and reliquefaction spaces, and the deck strips between them. The boundaries are not fixed. They move with the cargo, the ship's condition and whether tanks are inerted, so the plan is written per ship and per operation, not copied from a template. - Tank area and cargo manifold, including the spill containment around it. - Bunker and gas vent mast outlets, where vapour can drift with the wind. - Adjacent deck space within the agreed exclusion distance. ## Why hot work is the hard stop Hot work on or near a gas carrier is the activity most likely to be refused, delayed or moved ashore. Welding and cutting produce the ignition source that a gas-dangeous zone exists to keep away from vapour. The evidence from yards is blunt. A 2026 study in the Journal of Multidisciplinary Education examined the June 2025 fire on the tanker MT Federal II at PT ASL Shipyard in Batam and found the fire was caused by violations of safe working procedures on the hot work permit, lack of supervision and failure of personal protective equipment use ([Journal of Multidisciplinary Education](https://doi.org/10.23960/47rw5f14)). The pattern repeats across the region. A 2022 study in the Journal of Knowledge Industrial Engineering applied Job Safety Analysis and HAZOP at PT Cahaya Baru Shipyard and found most work accidents occurred in welding and cutting activities, at 23.3% of cases ([JKIE](https://doi.org/10.35891/jkie.v9i2.3287)). For a repair yard, that is the commercial translation: a hot work job without a valid permit is not a fast job, it is a stopped job with a fire risk attached. ## What the permit and the plan must line up on A hot work permit is only valid inside the terms of the gas-dangerous zone plan. If the two disagree, the more restrictive one applies. Item to confirmWhat the contractor needs Zone boundariesAgreed exclusion distance and marked deck limits before mobilising Gas readingsWho takes them, where, how often, and who signs off Permit validityStart and expiry time, and who can extend it SupervisionNamed ship or terminal representative present throughout Stop conditionsWhat triggers an immediate work stoppage Emergency responseAlarm, muster point and firefighting arrangement A 2024 study in the International Journal of Marine Engineering Innovation and Research mapped ship repair activity at a cooperative shipyard and recorded 26 activities across preparation, the docking process and post-docking work, identifying 40 hazard sources ([International Journal of Marine Engineering Innovation and Research](https://doi.org/10.12962/j25481479.v9i1.20084)). Risk assessment has to sit inside that flow, not beside it. ## Where gas carriers are actually calling Gas tonnage is moving through disrupted routes, which pushes more gas-related work into yards and anchorages outside the usual lanes. Qatar's gas exports were badly hit after a projectile attack on one of its tankers outside the Strait of Hormuz, forcing the producer to change how it ships ([gCaptain](https://gcaptain.com/qatar-rewrites-its-gas-playbook-with-old-tankers-and-new-tactics/)). European gas prices rose more than 3% on Persian Gulf disruption and UK inflation data, with the Dutch TTF front-month contract at 87.95 euros per megawatt-hour ([Hellenic Shipping News](https://www.hellenicshippingnews.com/european-gas-rallies-on-persian-gulf-disruption-pressure-hot-uk-inflation-dents/)). Higher gas values keep older tonnage trading, and older tonnage needs more repair attention. Conversions add another work stream. A 24-year-old jack-up is due at an Asian yard for a rig-to-MOPU conversion ahead of deployment at a Southeast Asian gas field ([Offshore Energy](https://offshore-energy.biz/2026/10/13/2002-built-jack-up-comes-to-asian-yard-for-mopu-conversion-ahead-of-gas-field-deployment)). Any such unit brings a gas-dangerous zone regime into a yard that may not handle gas tonnage every week. ## What to confirm before you quote Ask these questions at enquiry stage, not after mobilisation. Each one changes your price, your manning or your schedule. 1. Is the vessel carrying cargo, and will tanks be inerted or gas-free during my scope? 2. Who issues the hot work permit, and does the yard or the ship's DOC holder (the company named on the vessel's Document of Compliance) control it? 3. What exclusion distance applies to my deck work, and does it move during cargo operations? 4. Will cargo operations stop for the duration of my job, and who pays for that stoppage? 5. Is supervision included in the yard's price or charged as a separate line? If the answer to the first question is unclear, quote the job as conditional. A conditional quote protects you from a schedule you cannot control. For chandlers and agents, the same logic applies to deck deliveries. A PDA (proforma disbursement account, the agent's estimate of port costs) should carry an explicit line for any delay caused by restricted deck access during gas operations. Timing matters more than most suppliers assume. The earlier you know a gas carrier is inbound, the earlier you can confirm restrictions. Our guide to [reading vessel arrival alerts for suppliers](https://vesselreach.si/blog/vessel-arrival-alerts-for-suppliers-reading-ais) covers how to work from AIS and ETA data before the ship berths. ## How VesselReach helps Gas carrier work is won before the vessel berths, when you still have time to confirm restrictions and price the job properly. - **Vessel intelligence:** VesselReach shows vessels near your selected ports plus scheduled and expected arrivals, which means you can flag gas tonnage early and ask about zone restrictions before quoting. - **Decision-maker discovery:** VesselReach finds the operations, technical and fleet contacts behind each vessel, which means you reach the person who controls the permit and the yard slot rather than a general inbox. - **Multichannel outreach:** staged email, WhatsApp and phone contact keeps the enquiry moving, which means your conditional quote reaches the right desk while the berth window is still open. Book a VesselReach demo and see which gas carriers are heading for your ports this month. ## Frequently asked questions ### What is a gas-dangerous zone plan? It is the document that defines where flammable cargo vapour may be present on a gas carrier or at a gas terminal, and which work is restricted, permitted or banned in those areas. It sets the boundaries that hot work permits and deck jobs must respect. ### Can a repair yard do hot work on a gas carrier? Only under a valid hot work permit that matches the gas-dangerous zone plan, with gas readings, named supervision and agreed stop conditions. A 2026 study of the MT Federal II fire found permit violations, weak supervision and failed PPE use caused the blaze. ([Journal of Multidisciplinary Education](https://doi.org/10.23960/47rw5f14)) ### Why do welding and cutting dominate shipyard accidents? They combine ignition sources with confined or poorly ventilated spaces. A 2022 study at PT Cahaya Baru Shipyard found most work accidents occurred in welding and cutting activities, at 23.3% of recorded cases. ([JKIE (Journal Knowledge Industrial Engineering) (Universitas Yudharta Pasuruan)](https://doi.org/10.35891/jkie.v9i2.3287)) ### What should a chandler confirm before quoting a gas carrier call? Confirm whether cargo operations will restrict deck access, who supervises deliveries in the zone, and whether delays caused by restricted access are billable. Put any conditional access in the quote and the proforma disbursement account. ### How do I find gas carriers heading for my port? Track scheduled and expected arrivals rather than waiting for the ship to berth. VesselReach lists vessels near your selected ports plus expected arrivals, so you can approach the right company while there is still time to plan the job. ## Sources 1. [Evaluasi Penerapan K3 Mekanik pada Insiden Kebakaran Kapal MT Federal II di PT ASL Shipyard, Batam](https://doi.org/10.23960/47rw5f14), Journal of Multidisciplinary Education, 2026-05-20 2. [Minimizing Work Accidents in the Shipyarding Industry Using JSA and HAZOP Methods](https://doi.org/10.35891/jkie.v9i2.3287), JKIE (Journal Knowledge Industrial Engineering) (Universitas Yudharta Pasuruan), 2022-08-29 3. [Assessment of Occupational Safety Risks in Ship Repairs at the Fisheries Service Employees Cooperative Shipyard (FSECS)](https://doi.org/10.12962/j25481479.v9i1.20084), International Journal of Marine Engineering Innovation and Research (Sepuluh Nopember Institute of Technology), 2024-03-28 4. [Qatar Rewrites Its Gas Playbook With Old Tankers and New Tactics](https://gcaptain.com/qatar-rewrites-its-gas-playbook-with-old-tankers-and-new-tactics/), gCaptain, 2026-10-14 5. [2002-built jack-up comes to Asian yard for MOPU conversion ahead of gas field deployment](https://offshore-energy.biz/2026/10/13/2002-built-jack-up-comes-to-asian-yard-for-mopu-conversion-ahead-of-gas-field-deployment), Offshore Energy, 2026-10-13 6. [European gas rallies on Persian gulf disruption pressure; Hot UK Inflation dents](https://www.hellenicshippingnews.com/european-gas-rallies-on-persian-gulf-disruption-pressure-hot-uk-inflation-dents/), Hellenic Shipping News, 2026-10-21 ## More on this topic A gas dangerous zone plan sets out where flammable cargo vapour may be present on a gas carrier or at a gas terminal, and which deck work is restricted there. It decides whether your job starts, needs a hot work permit, or waits until tanks are gas-free. Studies of yard fires show permit violations and weak supervision behind the worst incidents, and welding and cutting account for most yard accidents. Before quoting, confirm cargo state, who issues the permit, the exclusion distance and who pays for supervision or stoppage. Chandlers and agents should carry the same restrictions into the PDA. VesselReach shows gas carriers due at your ports so you can confirm restrictions before berthing. The single most useful takeaway is that the gas-dangerous zone plan, not the hot work permit, sets the outer limit of what you can do on deck. Where the two documents disagree, the more restrictive one governs, so a permit that looks valid can still be void outside the agreed exclusion distance. Confirm zone boundaries, gas readings, permit validity, supervision and stop conditions at enquiry stage, and quote conditionally when the vessel's cargo state is unclear. --- VesselReach, built by CatalystIQ. CatalystIQ Data Classification and Analysis Services, Al Qusais, Dubai, P.O. Box 129882, United Arab Emirates. info@catalystiq.ae, +971 58 599 7894. Book a demo: https://vesselreach.si/#demo. Pricing: contact us for a quote (https://vesselreach.si/pricing).