Welding Machine Testing After Failure: What to Do When Safety Checks Don’t Pass

1. Welding Machine Testing: What to Do When Safety Checks Don’t Pass There’s that split second when the test result shows red — failed — and your gut drops. You might feel your face go hot, your chest tighten. Thoughts spiral: “Did I miss something?” “Will this shut us down?” “Am I in trouble?” The pressure is real — especially when you know your team relies on that machine to get through the week. And in most cases, you're not cutting corners. You’ve got procedures. You’ve done your checks. But sometimes, despite doing your best, something still slips through. That’s okay. This isn’t about blame — it’s about action. A failed welding machine testing result isn’t a death sentence for your operation. It’s an early warning — a sign to act now before someone gets hurt or before a regulator is asking hard questions. This article isn’t about general safety theory. It’s your real-world response playbook — built for the people who run the gear, manage the crews, and have to face the consequences when something goes wrong.

2. Step 1: Don’t Sweat It - Lock It Down When a machine fails testing, don’t keep using it. Don’t try to “just finish the job.” Immediately tag and lock it out following your LOTO (Lockout/Tagout) procedure. Tell your supervisor or safety officer — never try to quietly fix it yourself and move on. Even if you think it’s “just a loose lead” or “probably nothing,” it’s not worth the gamble. If this ever ends up in front of a regulator or insurance assessor, a clear, documented lockout shows that you acted in good faith.

3. Step 2: Time to Trace the Spark Pull the safety test report and look for: ● Error codes ● Flagged readings ● Notes from the testing technician Common causes for failed tests include: ● Earth leakage ● Damaged insulation ● Worn or faulty leads ● Internal electrical faults If the issue isn’t obvious, bring in a qualified person — an electrician or a certified welding technician — to inspect it properly. This isn’t just about fixing the fault, it’s about understanding why it happened. That knowledge is what prevents it from happening again. Step 3: Document Everything Write it all down. Log:

4. ● The failed result ● What the fault was ● Any initial observations ● Photos of the machine or issue (if relevant) ● The actions you took to isolate it Update your internal testing and maintenance records — even if the machine hasn’t been fixed yet. This shows you’re actively managing the risk, not ignoring it. Step 4: Repairs and Retesting Only qualified technicians should repair a failed welding machine. Never DIY something that requires licensed repair. Once the fix is made, the machine must be retested — ideally to AS/NZS 3760 or AS/NZS 60974.4 standards depending on the equipment. Don’t throw away the failed test report — keep both the failed and passed copies. They form a full paper trail of responsible management.

5. Step 5: Review Your Internal Systems Now’s the time to ask the hard question: Why did we miss this? ● Was the machine overdue for testing? ● Did a technician rush or overlook something? ● Was the fault developing slowly and missed during maintenance? Review your: ● Testing schedule ● Maintenance process ● Training refreshers ● Welding supplies quality (including leads, plugs, PPE) Failures aren’t always about the machine — sometimes it’s a symptom of worn-out systems or inconsistent habits. And yes, that includes checking the little things — like the condition of welding clamps or whether the team has been properly maintaining their welding helmets. Step 6: Be Ready for a Regulator Visit

6. If the machine failure caused or almost caused an incident — like an arc flash, electric shock, or equipment fire — you may need to report it to your state WHS regulator (e.g. SafeWork NSW, WorkSafe VIC, WorkSafe QLD). Even if there was no injury, a reportable near miss could trigger an inspection. Prepare by ensuring you have: ● Test logs and inspection reports ● Repair and retesting documentation Staff training records and certifications ● Updated SWPs and risk assessments You might get lucky with a verbal check — or you might be facing a full audit. Show that you’re fixing the root cause, not just patching the surface. And don’t forget to review auxiliary gear that may contribute to incidents — like missing flashback arrestors on oxy kits or mismatched power leads. Step 7: Communicate with Your Team A failed test shouldn’t be a dirty secret — it’s a learning opportunity.

7. Hold a short toolbox talk. Share: ● What happened ● Why it was caught ● What’s being done ● What they can do differently next time This builds a safety culture, not a blame culture. Your crew will appreciate transparency and feel more confident knowing that faults are being dealt with — not hidden or ignored. Experience is Your Best Mate – Next Time, You’ve Got This No one wants to deal with a failed test. It's stressful, confronting, and often inconvenient. It’s completely normal to feel panic or fear. And yes, some people react by cutting corners or hiding it — but that only piles on more risk. The best thing you can do? Follow the process. Tag it out. Fix it properly. Document every step. Not only does this show your crew that safety matters — it shows regulators, insurers, and stakeholders that you're in control.

8. Because if you think dealing with inspectors is hard, imagine having to sit down with the family of a worker who’s been seriously injured — or worse — because a machine wasn’t tested, reported, or repaired properly.That’s the kind of outcome that sticks with you forever. So don’t gamble with your team’s safety, or your own peace of mind. Let every test — even the failed ones — make you better, safer, and more prepared the next time around. If you want expert assistance in ensuring all your welding equipment is tested and up to standard, consider reaching out to WeldConnect’s expert technicians. They can help assess and test all your welding machinery and surrounding equipment to ensure safety and compliance. It’s a smart way to stay ahead of potential risks and keep your operation running smoothly. Frequently Asked Questions (FAQ) 1. How often should welding machines be tested for safety? Welding machines should be tested for safety at regular intervals, in compliance with standards such as AS/NZS 3760. The frequency may vary depending on the type of equipment, usage, and environmental conditions, but it’s typically recommended to test at least once a year. 2. What should I do if my welding machine fails testing? If your welding machine fails testing, follow the lockout/tagout (LOTO) procedure immediately to isolate the machine. Document the failure, investigate the cause, and contact a qualified technician for repairs. After repairs, ensure the machine is retested before it’s put back into service. 3. Who is responsible for welding machine maintenance in a workshop? The responsibility for welding machine maintenance generally falls on the workshop manager or designated safety officer. However, technicians who are qualified in welding equipment should handle repairs, while safety officers oversee regular inspections and documentation to ensure compliance.