Free checklist · Shop & tools
Welding equipment inspection checklist (free, printable)
Before each shift, check the welding machine's cord and grounding, the leads for damaged insulation or splices near the holder, the electrode holder's insulation and the work clamp. For gas work, check cylinders are secured upright with caps on when not connected, and regulators, hoses and torches don't leak. Then check the extinguisher, screens and combustibles around the job.
- How often
- Before each shift
- The rule
- OSHA 29 CFR 1910.254(d)
- Items
- 24 checks
- Takes
- About 6 minutes
By the CheckBadges team · Updated
Layout
Welding equipment inspection checklist
Before each shift
| Item | OK | Problem | N/A |
|---|---|---|---|
| Welding machine | |||
| Power cord and plugNo cuts or crushed spots; plug and ground pin intact. | |||
| Machine groundingFrame grounded through the cord or a ground lead; connection tight. | |||
| Case and controlsCovers on; switches and dials work; nothing loose or burned. | |||
| LeaksNo leaks of cooling water, shielding gas or engine fuel. | |||
| Engine fluidsOil, coolant and fuel checked on engine-driven welders. | |||
| Leads and connections | |||
| Electrode leadInsulation whole; no splices within 10 feet of the holder. | |||
| Work lead and clampClamp grips firmly; jaws clean of spatter; lead undamaged. | |||
| Electrode holderInsulation not cracked or burned; jaws grip the rod. | |||
| Cable connectors and lugsTight and fully insulated. | |||
| Leads laid outUncoiled and clear of walkways, ladders and water. | |||
| MIG or TIG torchNozzle and tip clean; trigger works; cable not kinked or cut. | |||
| Gas cylinders and oxy-fuel | |||
| Cylinders securedUpright and chained or strapped; key on the acetylene valve. | |||
| Valve capsOn every cylinder that isn't connected for use. | |||
| Cylinder storageStored oxygen 20 ft from fuel gas, or behind a 5-ft fire-rated barrier. | |||
| Regulators and gaugesRight gas; gauges readable; no oil or grease; seats sound. | |||
| Flashback arrestorsFitted as the manufacturer specifies; replaced after a flashback. | |||
| HosesNo burns, cuts or worn spots; oxygen and fuel hoses distinct. | |||
| Leak testSoapy-water test on valves, regulators and hose connections. | |||
| TorchValves shut off fully; tip clean; no leaks at couplings. | |||
| Work area | |||
| Fire extinguisherCharged extinguisher ready at the work area. | |||
| CombustiblesMoved 35 ft away or covered; floor swept clean. | |||
| Fire watchAssigned where combustibles are within 35 ft or sparks could reach them. | |||
| Screens and curtainsIn place to shield people nearby from the arc. | |||
| Helmet and lensShell not cracked; lens the right shade and not cracked. | |||
Problems found and action taken:
If anything is a problem, don't use the machine: tag it out and report it. Free checklist from checkbadges.com — put it on a QR sticker and operators can fill it in on their phone.
What to check on a welder, item by item
Welding machine
- Power cord and plug — No cuts or crushed spots; plug and ground pin intact.
- Machine grounding — Frame grounded through the cord or a ground lead; connection tight.
- Case and controls — Covers on; switches and dials work; nothing loose or burned.
- Leaks — No leaks of cooling water, shielding gas or engine fuel.
- Engine fluids — Oil, coolant and fuel checked on engine-driven welders.
Leads and connections
- Electrode lead — Insulation whole; no splices within 10 feet of the holder.
- Work lead and clamp — Clamp grips firmly; jaws clean of spatter; lead undamaged.
- Electrode holder — Insulation not cracked or burned; jaws grip the rod.
- Cable connectors and lugs — Tight and fully insulated.
- Leads laid out — Uncoiled and clear of walkways, ladders and water.
- MIG or TIG torch — Nozzle and tip clean; trigger works; cable not kinked or cut.
Gas cylinders and oxy-fuel
- Cylinders secured — Upright and chained or strapped; key on the acetylene valve.
- Valve caps — On every cylinder that isn't connected for use.
- Cylinder storage — Stored oxygen 20 ft from fuel gas, or behind a 5-ft fire-rated barrier.
- Regulators and gauges — Right gas; gauges readable; no oil or grease; seats sound.
- Flashback arrestors — Fitted as the manufacturer specifies; replaced after a flashback.
- Hoses — No burns, cuts or worn spots; oxygen and fuel hoses distinct.
- Leak test — Soapy-water test on valves, regulators and hose connections.
- Torch — Valves shut off fully; tip clean; no leaks at couplings.
Work area
- Fire extinguisher — Charged extinguisher ready at the work area.
- Combustibles — Moved 35 ft away or covered; floor swept clean.
- Fire watch — Assigned where combustibles are within 35 ft or sparks could reach them.
- Screens and curtains — In place to shield people nearby from the arc.
- Helmet and lens — Shell not cracked; lens the right shade and not cracked.
How often welding equipment has to be inspected
Check welding equipment before each shift, and the connections again before each job. OSHA's arc welding rule tells the welder what to look at before striking an arc: "Before starting operations all connections to the machine shall be checked to make certain they are properly made," the work lead "firmly attached to the work," the machine frame's grounding checked, and "no leaks of cooling water, shielding gas or engine fuel" (29 CFR 1910.254(d)(2)–(4)). Cables with splices within 10 feet of the holder can't be used ((d)(8)), and "Cables with damaged insulation or exposed bare conductors shall be replaced" ((d)(9)(iii)).
Oxy-fuel gear has its own rules:
- Construction: hose carrying fuel gas or oxygen "shall be inspected at the beginning of each working shift," and torches "shall be inspected at the beginning of each working shift for leaking shutoff valves, hose couplings, and tip connections" (29 CFR 1926.350(f)(3) and (g)(2)). Cylinders must be "secured in an upright position at all times" except briefly while being moved ((a)(9)).
- General industry: valve protection caps "shall always be in place, hand-tight, except when cylinders are in use or connected for use"; stored oxygen is kept 20 feet from fuel gas or behind a noncombustible barrier at least 5 feet high with at least a half-hour fire rating; hose "showing leaks, burns, worn places, or other defects" is repaired or replaced; and regulator union nuts and connections are "inspected before use" (29 CFR 1910.253).
- Fire protection: "Suitable fire extinguishing equipment shall be maintained in a state of readiness for instant use," and a fire watch is needed where appreciable combustibles are closer than 35 feet (29 CFR 1910.252(a)(2)).
How to do the check
- Look at the area first. Combustibles moved or covered, extinguisher in place, screens up.
- Check the machine with the power off. Cord, plug, case and grounding.
- Walk the leads from the machine to the holder and the clamp. Spread out any coiled cable; OSHA says coiled welding cable "shall be spread out before use to avoid serious overheating and damage to insulation" ((d)(2)).
- Check each cylinder is secured and labeled, then open its valve slowly.
- Set the regulators and leak-test every connection with leak-detection solution or soapy water. Never look for a leak with a flame.
- Strike an arc or light the torch on scrap and check it runs steadily before starting the job.
The defects that take it out of service
| Defect | Why it fails |
|---|---|
| Damaged insulation or a bare conductor on a lead | Shock risk; OSHA requires the cable replaced |
| Splice within 10 ft of the electrode holder | Not allowed under 1910.254(d)(8) |
| Cracked or burned electrode holder | Exposes live metal in the welder's hand |
| Machine frame not grounded | A fault can make the case live |
| Leaking hose, regulator or torch valve | A fire and explosion risk; defective hose comes out of service |
| Hose that has had a flashback | Must be tested before reuse (1926.350(f)(4)); most shops replace it |
| Unsecured cylinder or missing valve cap | A falling cylinder can break off its valve |
| Missing or damaged flashback arrestor | Nothing stops a flashback reaching the hose and regulator |
What to do when something fails
Shut the cylinder valves, switch off and unplug the machine, tag it, and report it. OSHA's maintenance paragraph says the operator "should report any equipment defect or safety hazard to his supervisor and the use of the equipment shall be discontinued until its safety has been assured. Repairs shall be made only by qualified personnel" ((d)(9)(i)). A cylinder with a leaking valve that won't stop when closed is taken outdoors away from ignition sources (1910.253(b)(5)(iii)(F)), and the gas supplier tells you what to do next. Use an out-of-service tag on the machine or cart, and see what to do when equipment fails inspection.
Keeping the record
OSHA doesn't ask for a written log of these pre-shift checks, but a dated record shows the hoses and torches were checked at the start of each shift, which is the construction rule's wording. Note hose and arrestor replacements in it too. See equipment inspection record keeping.
Doing it on a phone
A QR sticker on the welder or the cylinder cart lets the welder do this check on their own phone before the first arc of the day, with a photo of any damaged lead. CheckBadges emails the problem to you and warns the next person who scans the machine until it's fixed. See QR code equipment checklists.
Skip the clipboard
Put this welder inspection checklist on a QR sticker.
- Operators scan the sticker with their own phone's camera. No app, account or password.
- Anything marked Problem emails you right away, with photos, and warns the next operator.
- Every check is saved by machine with who did it and when. Print one or export a CSV.
Free for 3 machines. Every item above is already filled in — edit anything. No card.
Welder 1
Welder inspection checklist
Frequently asked questions
How often should welding hoses be inspected?
At the beginning of each working shift on construction sites (29 CFR 1926.350(f)(3)). In general industry, hose "showing leaks, burns, worn places, or other defects rendering it unfit for service" must be repaired or replaced (1910.253(e)(5)(v)), so check it before each use.
Do oxy-acetylene torches need flashback arrestors?
OSHA's general-industry text deals with backflow and flashback protection mainly for manifold and piping systems. For portable outfits, follow the torch and regulator manufacturer, who normally specify arrestors, and replace any arrestor or hose that has stopped a flashback.
How far apart must oxygen and acetylene cylinders be stored?
At least 20 feet, or separated by a noncombustible barrier at least 5 feet high with a fire-resistance rating of at least half an hour (29 CFR 1910.253(b)(4)(iii)). The rule covers cylinders in storage, not a pair connected on a cart for use.
Can you tape a damaged welding lead?
Not in general industry: cables with damaged insulation or exposed bare conductors "shall be replaced" (29 CFR 1910.254(d)(9)(iii)). Construction rules allow worn spots to be covered with rubber and friction tape, except within 10 feet of the electrode holder (1926.351(b)); a proper insulated connector is better anywhere.
How do you leak test an oxy-fuel setup?
With the regulators pressurized, brush leak-detection solution or soapy water on the cylinder valves, regulator connections, hose fittings and torch valves. Bubbles mean a leak. Never use a flame, and don't light up until every connection passes.
Keep reading
- Fire extinguisher inspection checklistFree monthly fire extinguisher inspection checklist and form: access, gauge in the green, pin and seal, hose, damage, label, weight and annual maintenance tag.
- Power tool inspection checklistFree power tool inspection checklist for corded, cordless and air tools: cords, plugs, guards, switches, blades, batteries and hoses. Print it or use it by QR.
- Air compressor inspection checklistFree air compressor inspection checklist: drain the tank, then check the safety valve, gauge, hoses, fittings, belt guard, oil and auto shutoff before use.
- Out-of-service tag makerPrint DANGER – DO NOT OPERATE and OUT OF SERVICE tags for defective equipment. Fill in the machine, problem and date, or leave blanks. Free, no signup.
- ManufacturingMachine pre-use checklists for manufacturing: a QR sticker on each press, saw, crane and forklift. Operators scan with their phone; problems alert you at once.
- ConstructionConstruction equipment inspections on a QR sticker per machine. Operators and subs scan with their own phone, no app or login. Defects email you with photos.
Do your welder checks by QR code.
Stick a QR code on every machine and operators do the pre-use check on their own phone — no app, no login. Free for up to 3 machines; try it with your real machines before you sign up.