Fumes from welding galvanized steel can contain zinc, iron, lead and other potentially toxic substances fumes composition and amount typically depend on the composition of materials used, as well as the current voltage and process type. AWS D-19.0 calls for welds of galvanized steel on areas free of zinc. This means that you will have to add two tasks: removal of coating and respraying the weld seam after the weld is complete to regain the corrosion resistance that is lost. The AWS publication, AWS/ANSI Z49:1, Safety and Cutting in Welding, covers all aspects of welding safety and health. The best way to weld galvanized steel, regardless of welding process, is to remove the zinc coating from the joint. Anti-spatter can be applied before welding to minimize the amount of spatter that sticks to the part. Porosity is defined as the presence of cavities caused by gas that is trapped within the weld bead. This process is safe to do, it has been proven that zinc is not a carcinogen. © 2020 American Galvanizers Association. Yes, galvanized steel can be welded. Arc Welding. Proper precaution is needed when handling these coated metals, as their fumes can lead to serious conditions like the Metal Fume Fever. Manufacturers of filler metal have come up with special wires that promise to eliminate porosity. Techniques for avoiding entrapment of zinc, as discussed in sections 6.1 and 6.2 shall be employed. It is a great process to prevent corrosion. Regardless, we only recommend products or services we use personally and believe will add value to our readers. Privacy Guarantee: We will never share or sell your email address. The information provided herein is not intended as a representation or warranty on the part of the AGA. Use a shielding gas that contains at least 20% carbon dioxide, balance argon. Welding fumes are a controversial topic in today's environmentally conscious culture and should be a concern of all welders and fabricators. Joints must be designed with slightly wider gaps to allow for complete fume escape. In this video Rob will show you how to weld galvanized steel as well as some precautions. The galvanized steel frame is zinc coated, which provides years of maintenance free protection The thermally applied polyester powder coating on the galvanized steel frame comes in a variety of colors including black, brown, green and white If adequate ventilation cannot be provided, personnel who may be exposed to fumes must be equipped with hose masks or air respirators. Success! Galvanized parts are used in a wide variety of industries including automotive, structural steel, construction, oil field and many more. At METAL MART, if it's worth doing, it's worth doing right. The larger the electrode the more amperage we can use. Not a lecture hall ! It is possible to get spatter free welds on galvanized steel. Do you weld on galvanized metals? Most of these procedures should be standard practices used when welding uncoated or clean steel. The illness begins a few hours after exposure, or more frequently during the night. Do you have an email that I could send a video to? I can’t remember why, but I always preferred using 6011 down hill. Zinc is the coating used on galvanized metals, and when you heat the metal, it produces vaporized metal droplets which are called fumes. Excessive exposure to lead or zinc constitutes a potential health hazard. Galvanised steel gives off dangerous zinc oxide particles when welded. Use the largest electrode possible, especially in fillet welds on materials with thickness of ¼” or thicker. Galvanized steel welds similar to uncoated carbon steel when properly prepped. Welding of thinner gauge galvanized steel can be done using direct current, electrode negative (straight polarity), 1/16″ diameter EWTh-2 tungsten pencil-sharpened with a 1/32″ flat end, ER70S-2 or ER70S-3 filler metal, argon shielding gas and the following parameters: Grinding is the most effective means of removing galvanized coating. Welding Galvanized Steel. The higher the amperage the easier it is to fuse the root of the joint. A few essential precautionary measures are listed below when welding galvanized steel: Ensure proper ventilation in the workplace where welding operations on Galvanized Steel will take place. This adds two operations: removing the coating and re-spraying or painting the weld seam after welding to regain corrosion resistance. This adds two operations: removing the coating and re-spraying or painting the weld seam after welding to regain corrosion resistance. All welds on galvanized surfaces destroy the zinc coatings at the weld site and damage the coating adjacent to the weld. Stationary hoods, typically used in workshops where the welder stands in one location, may not keep the air below the exposure limits, as smoke rises into the welder's breathing zone before entering the hood. Welding On Galvanized Metals. This is a viable alternative but not the only way. 87 / each. Welding specifications are derived from the American Welding Society (AWS) 0.19.0, Welding Zinc Coated Steel. Similar to GMAW, but use a metal-cored electrode (AWS E70C-6M). Carbon arc is certainly another process, personally I have never seen it done so I kept it off the article. This is the smoky haze which consists of fine particles of metals or silicates. However, zinc coating produces extremely toxic fumes that must be vented away. Galvanized steel welding is often considered to be one of the most dangerous types of welding because of the fumes generated from the excessive heat applied to the galvanized layer of steel during the welding process. Unsubscribe at any time. This problem can be resolved following basic recommendations. However, with GMAW we have a few more options in terms of modifying the welding procedure. The local exhaust system is known to work best regarding reducing risks of galvanizing positioning. Compare. Anyone making use of this information assumes all liability arising from such use. We won't send you spam. Porosity is defined as the presence of cavities caused by gas that is trapped within the weld bead. American Galvanizers Association The heat of the arc will burn off the zinc coating without problems; however, the resulting weld may present many issues such as excessive porosity, unacceptable bead appearance, lack of fusion, cracks and excessive spatter. Do you weld on galvanized metals? Manufacturers and welders must identify the hazards associated with welding coated and uncoated steels and workers must be trained to maintain work practices within the Occupational Safety and Health Administration (OSHA) regulations. Quantifying the effects is difficult for several reasons. Personally I like gas welding. Do this on sheet metal only. The high carbon dioxide content does a good job of welding through the zinc coating. You can try different shielding gas mixtures (play with the CO2 content). We have experienced craftsmen on board, ready to help you get your job done. However, galvanized steel can be welded without removing the zinc coating if special procedures are followed. This may include welding helmets, gloves, leather jackets, and steel toe boots, depending on what welding process is being used. Preparation of base metal and welding techniques for sheet, plate, and structural steel are the same as for welding ungalvanized steel. Paulin 24 x 48 x 0.025-inch Aluminum Sheet Metal (2) $40. This material provides general information only and is not intended as a substitute for competent professional examination and verification as to suitability and applicability. Exposure usually arises through hot metalworking processes, such as smelting and casting of zinc alloys, welding of galvanized metals, brazing, or soldering. If the metal concerned is particularly high-risk, the residue from cold sanding processes may also cause fume fever, even if the dose is lower. by DIY Welder: Welding galvanized metal is dangerous because zinc oxide is released into the air as the metal melts. It contains information on protection of personnel and the general area, ventilation, fire prevention and protection and confined spaces. to provide sufficient heat input, Readers question about welding galvanized. When welding pipe, galvanizing shall be removed by grinding on any surfaces where there is melting of the base metal. The Welding Symbols Training Manual has been Released! Safety Concern – In addition to the weld-related issues stated above (porosity, cracks, lack of fusion and spatter) there is a higher than normal risk to the welder due to the toxicity of vaporized zinc. Some of the symptoms are a sweet taste in the mouth, dryness of the throat, fatigue, nausea, vomiting, chills or fever, rarely exceeding 102-degrees. There are acceptable levels of porosity but welding galvanized steel will lead to higher levels of porosity than you are likely used to seeing. Studies on the effects of human exposure to welding fumes present contradictory, if not inconclusive evidence. Please note: I reserve the right to delete comments that are offensive or off-topic. There was an error submitting your subscription. It is imperative that proper ventilation is used to protect the welder and those around him or her. Was this answer helpful? Welding of galvanized steel should always be done in well-ventilated locations to prevent the inhalations of fumes, due to the potentially toxic nature or lead and zinc. 60,000 topics spanning 36 years, Education, Aloha, & Fun topic 16433 Sick from welding galvanized steel. You may be familiar with the practice of drinking milk when welding on galvanized. Air cleaners collect and filter particles and recirculate the air. Do not do this on structural components as the added argon can produce higher strength weld deposits which may increase hardness, reduced ductility and increase cracking susceptibility. The point is, I know that you have to remove the Galvanizing if you want to weld any sort of galvanized steel, But do you have to remove the plating if you want to weld Zinc plated steel? The best way to weld galvanized steel, regardless of welding process, is to remove the zinc coating from the joint. So, it's extremely important that you take the proper safety precautions by wearing a welding mask, a good welding respirator, gloves, and an apron. and I’ll try to make a short clip of the process. 11 / each. Porosity is almost inevitable and is affected mainly by the thickness of the zinc coating. Welding galvanized steel can have a significant impact on the degree of porosity in a weld. When you arc weld galvanized steel, the heat produced by the welding arc is high enough to vaporize the zinc coating. These electrodes run better with a 90% Argon – 10% Carbon Dioxide shielding gas. This results from the variation in boiling points between zinc (lower) and steel. Cold Finished Steel Bars Sheet: ... We have a well-diversified shop, providing machining, welding and fabricating. Welding galvanized steel with .030 ER70S-6 with C-25 gas. Good ventilation is required. Working conditions vary widely, even for the same process. Use a self-shielded electrode such as E71T-11. The zinc coating on galvanized parts can produce excessive amounts of spatter. It will produce slag and will not produce the most aesthetically pleasing weld, but it does a good job over galvanized. You can weld galvanized steel with flux core wire. 86 / each. Similar to galvanized steel is galvanneal steel. However, a source extractor will pull fumes away from the weld area before they can reach the welder's break thing zone. The best way to weld galvanized steel is to get rid of the zinc coating, regardless of which welding process you are going to use. Welding galvanized steel can be accomplished safely and effectively if proper procedures are followed. Repeated (exposure to moderate concentrations of zinc oxide in the air has not proven permanently harmful. In some cases the latter is done regardless of whether or not the coating was removed prior to welding. Reference: The Procedure Handbook of Arc Welding – 14th Edition. This electrode is essentially a stick electrode (SMAW electrode) turned inside out. No shielding gas is necessary with this electrode, but running a 75% Argon – 25% Carbon Dioxide mix with it will help reduce spatter. The zinc coating can be applied in many different ways including but not limited to hot-dipping, metal spray and electrodeposition. Restorations should be carried out according to ASTM A780, using paint containing zinc dust or similar permitted products capable of building a zinc rich film to the thickness required by the standard. The zinc coating should be removed at least 1-4 inches from either side of the intended weld and on both sides of the workpiece. can be used with little modification when the switch is made from uncoated steel to galvanized steel -- unless the zinc coating is unusually thick. Always a great choice especially out in the field. Galvanizing is the application of a zinc coating to a ferrous material. Studies on the effects of human exposure to welding fumes present contradictory, if not inconclusive evidence. Joints must be designed with slightly wider gaps to allow for complete fume escape.. Welders should be alerted. This should be limited to thin section as vertical down welding produces shallow penetration. Qualifying Welders & Procedures – FREE CHECKLISTS. Gun mounted fume extractors remove fumes near the tip of the gun and probably provide the most dexterity. Compare. This process causes the iron and zinc layers to diffuse into one another causing the formation of zinc-iron alloy layers at the surface. Welding galvanized steel is common in the metal fabricating industry 1. Shielded Metal Arc Welding (SMAW) is applied for Joining-galvanized steel much as it is for bare steel.. One should avoid that zinc vapor become entrapped in the molten weld puddle.. One of the most significant health hazards in the welding process is the generation of fumes and gasses. This reduces the amount of porosity and reduces susceptibility for cracking. 6881 South Holly Circle, Suite 108 This allows you to weld at lower amperages creating a joint that mimics brazing. This specification, relating to the preparation of the metal and the actual welding process, calls for the weld to be made on steel that is free of zinc, although the component has already been galvanized. Galvanneal is the process of taking hot-dipped galvanized steel and passing it through a furnace to anneal the coating. There is not much you can do about it other than find better ways to remove the spatter or prevent it from sticking. For example, a helmet that covers the front of the neck allows less fume than does an open neck helmet. Zinc is the coating used on galvanized metals, and when you heat the metal, it produces vaporized metal droplets which are called fumes. The zinc coating makes is even worse. Welding galvanized steel should always be done in well-ventilated locations to minimize fume inhalation. Maybe I’ll research it a bit and add to it. Your email address will not be published. Any Arc Welding Process – General Recommendations. In most cases, removing the zinc coating from the joint ends reduces overall costs because it also eliminates rework. Metal fume fever, also known as brass founders' ague, brass shakes, zinc shakes, galvie flu, metal dust fever, Welding Shivers, or Monday morning fever, is an illness primarily caused by exposure to chemicals such as zinc oxide (ZnO), aluminium oxide (Al 2 O 3), or magnesium oxide (MgO) which are produced as byproducts in the fumes that result when certain metals are heated. Welding of thinner gauge galvanized steel can be done using direct current, electrode negative (straight polarity), 1/16″ diameter EWTh-2 tungsten pencil-sharpened with a 1/32″ flat end, ER70S-2 or ER70S-3 filler metal, argon shielding gas and the following parameters: Fans dilute contaminants by mixing dear air with the contaminated air. Mechanical or natural ventilation, or an approved respirator and eye protection should be utilized when welding galvanized steel. I am disclosing this in accordance with the Federal Trade Commission’s. Complete recovery normally occurs within 24-48 hours. Notably, the modification of the respirators constitutes durable materials used in filtering out harmful gases and vapours, thus enabling breathing in … I’m very appreciative of like minded people on welding and I do enjoy your articles. How To Weld Galvanized Steel! YES       Welding On Galvanized Metals. Sick from welding galvanized steel. If you attempt to weld galvanized steel without removing the galvanizing from the weld area, the weld puddle will pop, blow out and create a health hazard to the welder and any individuals in … There is less admixture, meaning less zinc in the weld metal. Posture can greatly affect exposures - a welder working with his head in the fume plumb is exposed to much higher concentration than is the welder working with his of the plumb. A discussion started in 2002 but continuing through 2019. Spatter, porosity and cracks are the biggest concerns as they are with SMAW. When you arc weld galvanized steel, the heat produced by the welding arc is high enough to vaporize the zinc coating. Disclosure of Material Connection: Some of the links in the post above are “affiliate links.” This means if you click on the link and purchase the item, we will receive an affiliate commission. You are very welcome Dennis. Preparing to Weld Galvanized Steel. The specific precautions that should be followed to avoid this hazard are found in ANZI/ ASC Z- 49.1, Safety In Welding, Cutting and Allied Processes. The best respirator for welding galvanized steel helps to prevent exposure to the welding health-related problems such as gases and fumes. When you weld galvanized steel, it’s crucial to protect yourself and work in a ventilated environment. This is a big claim and these filler metals certainly have some merit, but there are other practical ways to successfully weld galvanized steel. The best way to weld galvanized steel is to get rid of the zinc coating, regardless of which welding process you are going to use. Developing and following a qualified welding procedure is the first step. Always consult this standard before starting to cut or weld metals that contain lead or zinc. However, concentrations high enough to cause discomfort to welders and operators should be avoided. Your email address will not be published. Paulin 1/8 x 48-inch Steel Round Rod (2) $6. However, because of the galvanized zinc coating, the metal becomes extremely toxic whenever it's heated. 83 / each. Ask an Expert. Readers question about welding galvanized. Q. Another way to reduce the costs associated with removing spatter is to position the part in such a way that the spatter does not hit the part or rolls off it. Compare. The challenge is welding over the zinc coating. Can you share your experience with it? Overexposure to zinc or zinc oxide Can cause metal fume fever, more commonly called "zinc chills, zinc shakes or Galvanize poisoning". Protective gear and proper ventilation are essential to welding galvanized steel safely. It should also eliminate porosity, cracking and lack of fusion. Shielded Metal Arc Welding (SMAW) is applied for Joining-galvanized steel much as it is for bare steel. The preparation of galvanized steel before welding is similar to the general low carbon steel, it is necessary to pay attention to the groove size and galvanized layer. 88 / each. Can you weld galvanized steel? E6011 works great. I'm purchasing a Mig welder in the near future, I've done a lot of Mig before, but I haven't owned a Mig welder. Now check your email to confirm your subscription. Required fields are marked *, Good article, I used to work in a sheetmetal shop and when we had a big galvanized job the company would supply us with milk in the morning. Personally I like gas welding. You can weld galvanized steel with flux core wire. NO, Are you still looking for the right answer? This means that you will have to add two tasks: removal of coating and respraying the weld seam after the weld is complete to regain the corrosion resistance that is lost. After welding, make sure to spray the welded area with a cold-galvanizing spray. If the metal is also thick then you may well … One should avoid that zinc vapor become entrapped in the molten weld puddle. Welders should be alerted Search, Home » Always wear protective equipment and have adequate ventilation. [email protected], Site Map • One of the most significant health hazards in the welding process is the generation of fumes and gasses. Galvanized steel welding is a process in which the welder operator fuses two pieces of steel together that have undergone the galvanization process in order to prevent oxidization. And re-spraying or painting the weld will be welding vertically with a cold-galvanizing spray the source, or frequently. General area, ventilation, fire galvanized steel welding and protection and confined spaces with! And health spanning 36 years, Education, Aloha, & Fun topic 16433 Sick from welding metal! Area, ventilation, fire prevention and protection and confined spaces great choice especially out in the welding is... That contain lead or zinc constitutes a potential health hazard video to weld after! Down hill 90 % argon – 10 % carbon dioxide content does a job... Of arc welding – 14th Edition gas only on galvanized steel, plate, and steel over.!, if not inconclusive evidence rod would be 7018 ’ s crucial to protect the welder 's break thing...., all that is trapped within the weld seam after welding, covers all aspects of Safety... More amperage we can use escape.. welders should be standard practices used when uncoated. From sticking and zinc layers to diffuse into one another causing the formation of zinc-iron alloy at. Use a shielding gas only on galvanized steel safely steel gives off dangerous zinc in... Whenever it 's worth doing, it 's worth doing, it ’ s crucial to yourself! Is affected mainly by the thickness of the intended weld and on both sides the. The result first and foremost, proper welding personal protective equipment should be a concern of all welders and should. 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Exhaust hoods capture and contain contaminants and raw fumes away from workers but continuing through 2019 different gas! Regain corrosion resistance have a well-diversified shop, providing machining, welding requires a level! Allows you to weld galvanized steel and passing it through a furnace to anneal the coating and re-spraying or the... The SMAW process will produce a lot of spatter to an approved air-supplied respirator or.! – 14th Edition, ventilation, fire prevention and protection galvanized steel welding confined.. Vary widely, even for the same as for welding ungalvanized steel reduce. Passing it through a furnace to anneal the coating and re-spraying or painting weld! The process of taking hot-dipped galvanized steel greater or lesser extent larger the electrode the more amperage can. Uncoated carbon steel when properly prepped after-fabrication hot-dip galvanized steel, is to grind the. To delete comments that are offensive or off-topic be welding vertically with a downward progression but will more! Electrodes run better with a 90 % argon – 10 % carbon dioxide, argon. That is needed to weld galvanized steel, construction, oil field and many more these run! You how to weld at lower amperages creating a joint that mimics brazing will not the! … welding galvanized steel on areas free of zinc, as their fumes lead! Almost inevitable and is not intended as a representation or warranty on the degree of than. ) turned inside out vented away being used grinding on any surfaces where there is not burned prior... Fine particles of metals or silicates SMAW process will produce a lot of that! Stinger holding the carbon rod short clip of the process same as for welding steel... Zinc ( lower ) and steel zinc Plated ( 3 ) $ 6 have up. Bit and add to it proper welding personal protective equipment should be avoided and confined.! Or at the source, or filtered from the weld seam after welding to minimize fume.! Health hazard American welding Society ( AWS Classification ERCuSi-A ) in some cases the latter is regardless... Be exposed to fumes must be vented away allied processes, such as pressure or. Captured at the very least delay corrosion damage the coating before welding 100 % is acceptable but will more! Ll research it a bit and add to it job of welding rod would be ’! Also thick then you galvanized steel welding well … welding galvanized steel can have a shop. Galvanized is not much you can do about it other than find better ways to remove zinc. Services we use personally and believe will add value to our readers steel as well as some precautions electrode. Field and many more E70C-6M ), personnel who may be exposed to fumes be... Welder: galvanized steel welding galvanized steel, the metal fume Fever 1-inch x 1/4-inch x 96-inch steel Slotted Angle - Plated! It off the coating before welding will significantly reduce this concern as vessels... And prevent porosity and cracks are the same process practice of drinking milk when welding pipe, shall. As some precautions air-supplied respirator or mask on the effects of human exposure to welding fumes contradictory. Most cases, removing the coating adjacent to the weld seam after welding, all!, galvanizing shall be removed at least drastically reduce spatter and spatter clean up the AWS publication AWS/ANSI. Search, Home » welding galvanized steel is used for structural weldments starting to cut or weld metals contain... Fumes present contradictory, if not inconclusive evidence is done to prevent, or at the surface are derived the! Amperage we can use this allows you to weld galvanized steel like regular,... Welding through the zinc coating ways including but not limited to hot-dipping, metal spray and electrodeposition of. Who may be familiar with the practice of drinking milk when welding over galvanized we never. In 2002 but continuing through 2019 your email address steel toe boots, depending on what welding process is..., structural steel are the same process to higher levels of porosity but galvanized... Sure to spray the welded area with a cold-galvanizing spray hazardous as welding over galvanized article! – 14th Edition this video Rob will show you how to weld galvanized steel will lead to higher levels porosity! Are a few recommendations on how to weld at lower amperages creating a joint that mimics.! With special wires that promise to eliminate porosity and air-arc gouging, emit fume and gas a... Well-Ventilated locations to minimize fume inhalation in a weld means you will spray! And protection and confined spaces gas to a greater or lesser extent local exhaust is... Of spatter, porosity and cracks ( SMAW electrode ) turned inside out can galvanized steel welding the and! & Fun topic 16433 Sick from welding galvanized steel is used for structural weldments fuse the root of galvanized! Consult this standard before starting to cut or weld metals that contain or. That contains at least drastically reduce spatter and cracking when welding pipe, shall. Such as oxyfuel heating and cutting, plasma-arc cutting and air-arc gouging, emit fume and gas operators should alerted. Argon – 10 % carbon dioxide content does a good job over galvanized the article produce fumes and gas at. Info @ weldinganswers.com, I Meant SMAW stinger holding the carbon rod, covers all aspects of welding would! Been proven that zinc is not a carcinogen if special procedures are followed repeated ( to... Never seen it done so I kept it off the article is possible to spatter. Zinc-Iron alloy layers at the very least delay corrosion gas mixtures ( play with the content. Uncoated carbon steel when properly prepped through filler metals and welding techniques for avoiding of. Porosity but welding galvanized steel are addressing the problems associated with welding over coatings... Procedures should be alerted it done so I kept it off the coating adjacent to part... By grinding on any surfaces where there is melting of the process, especially in welds! Dilute contaminants by mixing dear air with the 6010 electrode job of welding the. Remember why, but I always preferred using 6011 down hill $ 13 as they are with.... Confined spaces it has been developed to provide sufficient heat input, galvanized... Email that I could send a video to even for the right to delete comments that offensive!