Back to Work: How to Prepare Your Welding Workshop

This approach helps avoid rushed purchases. It also makes it easier to distinguish equipment that is still operational from equipment that needs to be serviced, repaired or replaced.

Identify the jobs and welding processes planned for the return to work

The first check does not directly concern the equipment, but rather the workshop's requirements. Before inspecting the equipment, it is useful to identify the operations that will be carried out during the upcoming jobs.

Which metals will be welded? What thicknesses will be involved? Will the work take place in the workshop or on site? Will MMA, MIG/MAG or TIG welding be required? Answering these questions will help you prepare the appropriate equipment, consumables and protective equipment.

For mobile work or on-site repairs, a compact MMA welding machine may be preferable because it is easy to transport and standard electrodes do not require a gas cylinder. For regular steel work in the workshop, MIG/MAG welding can meet productivity and continuous welding requirements. TIG welding will generally be chosen for assemblies requiring greater precision and control of the weld pool.

When several welding processes are required, a multi-process machine can provide a degree of versatility. However, it remains essential to check that its capabilities are genuinely suited to the materials, thicknesses and anticipated level of use.

This preliminary assessment also allows you to prepare:

• Compatible torches and accessories;
• The appropriate filler metal;
• The required shielding gas;
• Wear parts suited to each torch;
• Workholding and preparation equipment;
• Personal and collective protective equipment.

If the workshop needs to replace or add to its equipment, the MIG/MAG, TIG, ARC/MMA and laser welding machines category allows you to compare the main types of machines.

For users putting together their first set of equipment, our article on equipment for beginner welders presents the essential items needed to learn and work in good conditions.

Check the overall condition of the welding machine

A welding machine that has remained unused for some time must be inspected before it is returned to service. Even if it was working correctly before the shutdown, it may have been exposed to dust, moisture, impacts or poor storage conditions.

Begin with an external visual inspection. The casing should not show any significant deformation, missing fasteners or marks suggesting that it has sustained an impact. Handles, wheels and supports must remain sufficiently stable to allow the machine to be moved safely.

Also check that the ventilation grilles and openings are not obstructed by dust. Insufficient cooling can trigger thermal protection and reduce equipment performance. Cleaning must be carried out in accordance with the manufacturer's instructions, with the machine switched off and disconnected from the power supply.

Electrical connections require particular attention. Visually inspect the condition of:

• The power cable;
• The electrical plug;
• The torch connectors;
• The earth connections;
• The welding cables;
• The remote control or foot pedal, when used.

A crushed, cut or burnt cable, or one with damaged insulation, must not be ignored. A makeshift repair is no substitute for work carried out by a qualified person. If there is any doubt about the electrical or electronic condition of the machine, it must be checked by a competent technician before use.

For a machine equipped with a cooling unit, check the coolant level and condition in accordance with the manufacturer's instructions. Also inspect accessible connections and hoses to identify any leaks or visible damage.

The machine should only be switched back on once these checks have been completed. Then carry out a test in a suitable environment, using the necessary protective equipment and a workpiece intended for this purpose. Listen for unusual noises, observe the stability of the arc, and check the operation of the display, controls and wire feed if the machine is equipped with them.

The aim is not to dismantle the machine or carry out a complex technical operation yourself. It is to identify visible faults and entrust work requiring specialist expertise to the maintenance team or after-sales service.

Inspect the torches, cables and wear parts

Welding quality does not depend solely on the power source. A poorly maintained torch, a damaged cable or an unsuitable wear part can interfere with arc ignition, wire feeding, gas shielding and arc stability.

Checks on a MIG/MAG torch

On a MIG/MAG system, inspect the cable assembly, handle, trigger and swan neck. Then check the components at the end of the torch:

• The gas nozzle;
• The contact tip;
• The gas diffuser;
• The wire liner;
• The seals and insulators;
• The wire feed rollers.

Spatter accumulated inside the nozzle can disrupt gas distribution. A worn contact tip or one with the wrong diameter can cause irregular wire feeding and poor current transfer. The liner must also be suitable for the type and diameter of wire being used.

Use the restart period to prepare a small stock of wear parts compatible with the most frequently used torches. This stock helps prevent a machine from being taken out of service because of an inexpensive but essential component.

Checks on a TIG torch

For a TIG torch, check the cable assembly, connections, handle and control system. Also inspect:

• The ceramic nozzle;
• The collet;
• The collet body;
• The gas lens, when used;
• The back cap;
• The tungsten electrode.

A cracked or dirty nozzle can disrupt the gas shielding. The electrode must be prepared according to the type of current, the material and the recommendations applicable to the welding process. A contaminated electrode can cause an unstable arc or introduce defects into the weld pool.

If several materials are used, it may be advisable to keep accessories intended for steel, stainless steel and aluminium clearly separated to limit cross-contamination.

Checks on MMA equipment

For MMA welding, inspect the electrode holder, cable and connection points. The electrode holder must hold the electrode securely without excessive play. The earth clamp must make sufficiently firm contact with the workpiece or the table provided for this purpose.

With all welding processes, a poor current return can disrupt the arc and cause abnormal heating at the connections. Contact surfaces must remain clean, and visibly damaged connectors must be replaced.

Take an inventory of welding consumables

A well-prepared restart requires stock suited to the work ahead. The aim is not to accumulate unnecessary consumables, but to have the items that are genuinely needed in the sizes and quantities suited to the workshop's activity.

For MIG/MAG welding, check the available wire spools, their diameter, grade and storage condition. A spool exposed to moisture, dust or contaminants can cause wire-feeding problems and affect weld quality.

For TIG welding, check the filler rods, tungsten electrodes and torch wear parts. The rods must be clearly identified and stored in a clean environment to prevent different grades from being mixed.

For MMA welding, inspect the condition of the electrodes and their storage conditions. Some types are more sensitive to moisture and may require special precautions specified by their manufacturer. An electrode with cracked or damaged coating, or one that has been stored incorrectly, should not be used without prior assessment.

The inventory should also include consumables indirectly related to welding:

• Nozzles and contact tips;
• TIG collets and collet bodies;
• Protective lenses for welding helmets;
• Anti-spatter products;
• Wire brushes;
• Cutting and grinding discs;
• Finishing abrasives;
• Markers and marking products;
• Compatible cleaning and preparation products.

To simplify future restocking, organise consumables by welding process, diameter, material and frequency of use. Each storage location should be clearly labelled. A minimum stock level can be set for the most frequently used items so that a new order is triggered before they run out.

This organisation also avoids using a consumable by default simply because the correct item cannot be found in the workshop.

Inspect the welder's protective equipment

Personal protective equipment should not be regarded as mere accessories. Its condition must be checked before work resumes and then regularly according to its use and the manufacturer's recommendations.

For welding operations, INRS lists eye and face protection, heat-resistant gauntlet gloves, suitable clothing, safety footwear and hearing protection, among other equipment. Respiratory protection may be required when collective protective measures cannot be installed or remain insufficient.
View the INRS occupational information sheet on metal welding.

Check the welding helmet

Inspect the condition of the shell, headgear, adjustments and protective lenses. An outer lens that is heavily scratched or covered with spatter can reduce visibility of the weld pool. Replacing it can improve comfort and precision without requiring the entire helmet to be replaced.

For an auto-darkening welding helmet, follow the inspection procedure specified by the manufacturer. Also check that the sensors are clean, the filter's protective lenses are in good condition and the available settings operate correctly.

The choice of welding helmet should take into account the welding process, frequency of use, desired comfort and the risks involved. You can browse the different welding helmets and masks, along with their replacement lenses, filters and accessories.

Inspect gloves and clothing

Gloves must be inspected at the seams, cuffs and areas exposed to heat. Leather that has become very hard, perforated or torn no longer provides the same conditions of use.

Also inspect jackets, aprons, trousers and other protective clothing. Look for holes, open seams, burnt areas and faulty fastenings. Clothing used for welding must remain suitable for the risks involved and be worn in accordance with its instructions.

Safety footwear must retain a sole in good condition, a working fastening system and an upper suited to the working environment. Safety glasses used for grinding and workpiece preparation must provide sufficient visibility and show no damage that could compromise their fit or protection.

All personal protective equipment for welding must be selected following an assessment of the workstation. INRS states that the choice of PPE depends in particular on the risks, the characteristics of the task and the performance indicated in the product instructions.

Check the welding fume extraction and ventilation systems

Welding fumes should not be addressed simply by opening a door or window. Preventive measures must be designed according to the welding process, filler metal, material, workpiece configuration and workplace.

INRS recommends capturing fumes as close as possible to their source. Depending on the installation, this can be achieved using a fume extraction torch, an articulated extraction arm, a backdraught hood, a downdraught table or another suitable device. General ventilation complements this localised protection.

Before work resumes, inspect the accessible parts of the system:

• The condition of the extraction arm and hood;
• The movement of the joints;
• Visible hoses and ducts;
• The connections;
• The condition of the filters or their level of clogging;
• The operating indicators;
• The power supply;
• The extracted-air discharge area.

An extraction arm that is difficult to position may be placed too far from the source of the fumes. Extraction efficiency depends heavily on its position. It must be used in accordance with the installation requirements, without obstructing the welder's movements or disrupting the gas shielding.

The sound of suction alone is not enough to prove that the system is working correctly. Technical inspections, airflow measurements and maintenance operations must be carried out in accordance with the manufacturer's recommendations and the company's procedures.

When fixed extraction is not suitable for the work being carried out, a mobile fume extractor, a fume extraction torch or a portable solution may be considered after assessing the requirements. The welding fume extraction category presents various solutions for workshops and mobile work.

Personal respiratory protection should not be used automatically to compensate for collective protection that is absent or poorly maintained. It complements other measures when the risk assessment shows that additional protection is still required.

Check the tables, clamping equipment and preparation tools

Restarting the workshop is also an opportunity to inspect the welder's immediate working environment. A cluttered table, incomplete clamping accessories or worn preparation tools can slow work down and affect the consistency of assemblies.

Begin by cleaning the work area and removing unnecessary items. Inspect the stability of the table, the condition of the tabletop and the accessories used to position workpieces. Reference surfaces must remain clean enough to allow accurate positioning.

Then check:

• Pliers and clamps;
• Magnetic squares;
• Stops;
• Clamping components;
• Torch holders;
• Work stands and trolleys;
• Protective screens and curtains;
• Measuring and marking tools.

Insufficient clamping can cause the workpiece to move during tack welding or welding. Conversely, poorly distributed holding points can contribute to distortion. Accessories must therefore be selected according to the shape, weight and dimensions of the workpieces.

Welding tables and their accessories make it possible to organise the positioning, clamping and assembly of components within a structured workspace.

Workpiece preparation equipment must also be checked. Inspect the condition of the grinders, brushes and drilling equipment used in the workshop. Abrasive discs must be compatible with the machine, material, operation and intended rotational speed. A damaged disc must not be used.

Keep brushes and abrasives intended for steel, stainless steel and aluminium separate to reduce the risk of cross-contamination between materials. The equipment required for cutting, grinding, drilling and finishing is grouped in the drilling and abrasives category.

Finally, make sure that cables, pipes and hoses do not create obstacles in walkways. Gas cylinders must be installed, handled and stored in accordance with the applicable guidelines and their suppliers' instructions.

Plan maintenance and prioritise replacements

At the end of the inspection, the workshop will generally have a list of actions to complete. They will not all have the same level of urgency, so it is useful to group them into three priority levels.

Safety first

Equipment with damage that could affect safety must be taken out of service until it has been inspected, repaired or replaced. This applies in particular to damaged cables, faulty PPE, inadequate extraction systems or tools with a visible fault.

Prioritise continuity of operations

Next come items that could take a machine out of service or interrupt production: a faulty torch, missing wear parts, incompatible feed rollers, a lack of filler metal or insufficient stocks of essential consumables.

Keeping a small stock of strategic items helps prevent a simple contact tip, nozzle or helmet lens from holding up a job.

Prioritise productivity and comfort

Finally, some investments are not essential for an immediate return to service but can improve organisation and working conditions: a more suitable table, clamping accessories, mobile storage, a more ergonomic torch, a helmet offering better visibility or an extraction system that is easier to position.

The return-to-work period can be a good opportunity to compare equipment and take advantage of a special back-to-work selection. However, any purchase should remain guided by actual requirements, compatibility with existing equipment and frequency of use.

To make future inspections easier, create a simple record showing:

• The date of the last internal inspection;
• Any faults identified;
• Parts replaced;
• Items to order;
• Reorder thresholds;
• Work entrusted to the after-sales service;
• The next recommended maintenance operations.

This record turns the back-to-work inspection into a genuine preventive maintenance process.

Prepare your workshop to resume work in good conditions

Preparing to resume work does not necessarily mean replacing all the equipment. Its primary purpose is to establish the actual condition of the workshop and take action before a breakdown, shortage of consumables or faulty equipment disrupts operations.

The inspection should begin by identifying the upcoming jobs, followed by checks of the welding machine, torches, cables, consumables, PPE, fume extraction and workstation layout.

This approach helps prioritise purchases: protecting operators, keeping equipment available and gradually improving productivity. Technical, electrical or ventilation work requiring specialist skills must always be entrusted to qualified professionals.

By anticipating these eight checks, the workshop can resume operations with better-organised equipment, consumables on hand and equipment suited to the planned work.