A metalworking shop has unique infrastructure demands that set it apart from other workshop types. Welding, plasma cutting, grinding, and machining require robust electrical systems, high-capacity compressed air, effective ventilation, and careful attention to fire safety. Whether you are setting up a hobby fabrication space in your garage or planning a professional metal shop, understanding these requirements upfront prevents costly mistakes and ensures you can work safely and efficiently. Many aspiring metalworkers underestimate the electrical demands of welders and plasma cutters, or discover their compressor cannot keep up with continuous grinding. This comprehensive guide helps you plan every aspect of your metal shop infrastructure, from calculating compressor CFM for your air tools to sizing electrical service for heavy equipment. Our calculators provide specific recommendations based on your equipment and work patterns, helping you build a shop that handles everything from light fabrication to serious production work.
Metalworking equipment places exceptional demands on shop infrastructure. A typical MIG welder draws 30-50 amps at 240 volts, while plasma cutters, TIG welders, and air compressors add to the electrical load. Running these on inadequate wiring causes tripped breakers, voltage drops that affect weld quality, and potential fire hazards. Compressed air tools like die grinders and cutoff wheels can demand 6-10 CFM continuously, quickly overwhelming small compressors. Without proper planning, you will find yourself constantly waiting for pressure to recover or dealing with weak tool performance.
Safety considerations are equally important in metal shops. Welding produces toxic fumes that require proper ventilation. Grinding and cutting create sparks that can ignite combustibles. Metal shavings create slip hazards and can damage other equipment. Hot metal pieces need designated cooling areas. A well-planned metal shop addresses all these concerns systematically, creating a workspace where you can focus on your projects rather than fighting your infrastructure. Use our calculators to size your air system, electrical service, and climate control for the specific demands of metalworking.
Size your compressor for impact wrenches, grinders, plasma cutters, and spray guns.
Calculate NowCalculate electrical needs for welders, plasma cutters, and compressors.
CalculateSize your heating system for comfortable year-round metalwork.
CalculateDesign your metal shop layout with proper clearance and safety zones.
Plan LayoutSize electrical wiring for welders and high-draw equipment.
CalculateFind correct drill sizes for threading operations.
CalculateWelding equipment has the highest electrical demands in most metal shops. A small MIG welder might run on a standard 120V/20A circuit, but serious welding requires 240V service. Plan for at least a 50-amp 240V circuit for your primary welder, with additional circuits for plasma cutters and compressors. A 100-amp subpanel is common for dedicated metal shops. Consider voltage drop on long runs, as welders are sensitive to low voltage. Our Electrical Load Calculator helps you size your service correctly.
Metal shops rely heavily on compressed air for die grinders, cutoff wheels, impact wrenches, sandblasting, and plasma cutting. These tools often demand more CFM than woodworking equipment, and many run continuously rather than intermittently. A 60-gallon two-stage compressor with 10+ CFM at 90 PSI is a practical minimum for serious metalwork. Plasma cutters have specific air quality requirements, so include proper filtration and moisture separation. Our Air Compressor Calculator factors in the demanding needs of metal shop tools.
Welding fumes, grinding dust, and cutting smoke create serious health hazards that require active management. At minimum, position a fan to move contaminated air away from your breathing zone. Better solutions include downdraft tables for grinding, portable fume extractors for welding, or a dedicated exhaust system with makeup air. Consider the interaction between ventilation and heating, as extracting shop air in winter means heating replacement air. Some operations like galvanized welding or certain alloys require respiratory protection regardless of ventilation.
Metal shops produce sparks, hot metal, and flammable grinding dust that demand serious fire safety attention. Keep fire extinguishers rated for metal fires (Class D) as well as standard ABC extinguishers readily accessible. Create designated welding areas with non-combustible surroundings and welding curtains to contain sparks. Establish cooling areas for hot workpieces away from traffic patterns. Store compressed gas cylinders upright and secured. Keep floors clean of metal shavings and oily rags, and dispose of grinding waste properly. These precautions become habit with practice but must be designed into your shop layout.
Complete guide to planning and equipping your metalworking shop.
Read GuideTop compressor picks for metalworking applications.
View RecommendationsComprehensive guide to workshop air compressor systems.
Learn MoreWorkshop electrical requirements for high-demand equipment.
Learn MoreWhen setting up a metal shop, prioritize infrastructure before tools. The best welder in the world is useless without adequate electrical service to power it. Start with electrical, as upgrading later is disruptive and expensive. For most hobby fabrication shops, a 100-amp subpanel provides comfortable headroom for current equipment and future additions. Install dedicated 240V circuits for your welder, plasma cutter, and air compressor from the beginning, even if you start with smaller 120V equipment.
For compressed air, resist the temptation to start small with plans to upgrade later. A quality 60-gallon two-stage compressor will serve you for decades, while a small pancake compressor becomes a frustration within weeks of serious metalwork. Look for units with at least 10 CFM at 90 PSI and oil-lubricated pumps for longevity. If you plan to do plasma cutting or spray painting, invest in proper air filtration and drying equipment from the start.
Welding equipment choices depend on your primary work. MIG welders offer the fastest learning curve and work well for most fabrication. TIG provides the cleanest welds and works on more materials but requires more skill. Stick welding is most forgiving of dirty or rusty metal and works outdoors. Many shops eventually have all three types. Start with a good quality MIG in the 200-250 amp range with 240V capability, as this handles most hobby and light professional work. Buy the best welding helmet you can afford, as it directly affects weld quality and eye safety. For plasma cutters, a 40-50 amp unit cuts up to half-inch steel and covers most fabrication needs.
Most plasma cutters need 4-8 CFM at 60-90 PSI. A 30-gallon compressor with 5+ CFM handles occasional cutting. For production work, consider a 60-gallon with 10+ CFM. Always check your specific plasma cutter's requirements as they vary by amperage and cutting capacity. Clean, dry air is critical for plasma cutting quality, so include proper filtration and moisture separation in your air system.
Small MIG welders run on 120V/20A circuits. Larger MIG and TIG welders need 240V with 30-50 amp circuits. Always install a dedicated circuit for welding since shared circuits lead to tripped breakers and inconsistent arc performance. Some industrial welders require 3-phase power. Check your welder's nameplate for exact requirements and use our Electrical Load Calculator to plan your overall shop electrical.
Yes, proper ventilation is essential for welding safety. Welding produces fumes containing metal oxides and other compounds that can cause serious respiratory issues with prolonged exposure. At minimum, use a fan to move air away from your breathing zone. For enclosed spaces or frequent welding, install a fume extractor with a capture hood positioned near the weld. Some materials like galvanized steel, stainless, or certain alloys require respiratory protection regardless of ventilation.
Sealed concrete is the most practical flooring for metal shops. It is durable, easy to clean, and fire-resistant for welding sparks. Avoid rubber mats near welding areas as sparks can burn through them. Anti-fatigue mats are helpful at workstations but should be fire-resistant versions designed for welding environments. Keep floors clean of metal shavings to prevent slips, and sweep regularly since accumulated chips become a fire hazard when mixed with grinding sparks.
Start with adequate electrical since this is the biggest infrastructure need. Install at least a 60A subpanel with 240V circuits for welders and compressors, though 100A is better for future expansion. Add proper ventilation for welding fumes through fans or fume extractors. Plan for compressed air with a 30+ gallon compressor minimum, larger for plasma cutting. Consider fire safety with extinguishers and spark-resistant surfaces around welding areas. Use our calculators to size each system appropriately for your specific equipment and space.