When you arc weld galvanized steel, the heat produced by the welding arc is high enough to vaporize the zinc coating. The zinc coating makes is even worse. It will produce slag and will not produce the most aesthetically pleasing weld, but it does a good job over galvanized. Not a lecture hall ! Your email address will not be published. Terms of Use • 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. American Galvanizers Association Similar to galvanized steel is galvanneal steel. 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. This may include welding helmets, gloves, leather jackets, and steel toe boots, depending on what welding process is being used. Success! Compare. 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. One should avoid that zinc vapor become entrapped in the molten weld puddle. There is not much you can do about it other than find better ways to remove the spatter or prevent it from sticking. It is a great process to prevent corrosion. It should also eliminate porosity, cracking and lack of fusion. A discussion started in 2002 but continuing through 2019. You are very welcome Dennis. The zinc coating on galvanized parts can produce excessive amounts of spatter. This problem can be resolved following basic recommendations. Welding galvanized steel can have a significant impact on the degree of porosity in a weld. Quick Links • We have at times silicon bronze welded with a type of carbon arc and with GTAW. Manufacturers of filler metal have come up with special wires that promise to eliminate porosity. Protective gear and proper ventilation are essential to welding galvanized steel safely. Overexposure to zinc or zinc oxide Can cause metal fume fever, more commonly called "zinc chills, zinc shakes or Galvanize poisoning". How To Weld Galvanized Steel! 6881 South Holly Circle, Suite 108 If using short-circuit transfer in thinner parts using 100% is acceptable but will generate more spatter. Galvanizing is the application of a zinc coating to a ferrous material. 83 / each. E6011 works great. Shielded Metal Arc Welding (SMAW) is applied for Joining-galvanized steel much as it is for bare steel. Yes, galvanized steel can be welded. Similar to GMAW, but use a metal-cored electrode (AWS E70C-6M). Sick from welding galvanized steel. The best respirator for welding galvanized steel helps to prevent exposure to the welding health-related problems such as gases and fumes. 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. The local exhaust system is known to work best regarding reducing risks of galvanizing positioning. This process is safe to do, it has been proven that zinc is not a carcinogen. The intoxication caused by the vaporized zinc affects the stomach; the milk helps alleviate the discomfort, but does not eliminate the toxic effects. 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. 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. Of course, removing the zinc before welding will significantly reduce this concern. Personally I like gas welding. back to menu ↑ More about the Metal Fume Fever. I believe that you have my email. 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. 60,000 topics spanning 36 years, Education, Aloha, & Fun topic 16433 Sick from welding galvanized steel. Welding on galvanized steel can be necessary if the final structure is too large to be dipped in a galvanizing bath or for structures that must be welded in the field. However, zinc coating produces extremely toxic fumes that must be vented away. Techniques for avoiding entrapment of zinc, as discussed in sections 6.1 and 6.2 shall be employed. Welders should be alerted Readers question about welding galvanized. -- a roundtable with a seat for you. Do this on sheet metal only. Newsletter Signup: Sign up for Galvanizing Insights, the AGA's quarterly specifier e-newsletter. There is less admixture, meaning less zinc in the weld metal. It is done to prevent, or at the very least delay corrosion. I am disclosing this in accordance with the Federal Trade Commission’s. Exposure usually arises through hot metalworking processes, such as smelting and casting of zinc alloys, welding of galvanized metals, brazing, or soldering. However, because of the galvanized zinc coating, the metal becomes extremely toxic whenever it's heated. Most of these procedures should be standard practices used when welding uncoated or clean steel. If the galvanized is not burned off prior to welding then a poor weld will be the result. There are acceptable levels of porosity but welding galvanized steel will lead to higher levels of porosity than you are likely used to seeing. and I’ll try to make a short clip of the process. There was an error submitting your subscription. Thanks again , Dennis. Zinc is the coating used on galvanized metals, and when you heat the metal, it produces vaporized metal droplets which are called fumes. 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 allows you to weld at lower amperages creating a joint that mimics brazing. Welding galvanized steel is common in the metal fabricating industry 1. Use an inline whipping technique, the back and forth motion will help vaporize the zinc coating and prevent porosity and cracks. The high carbon dioxide content does a good job of welding through the zinc coating. In this video Rob will show you how to weld galvanized steel as well as some precautions. Always a great choice especially out in the field. © 2020 American Galvanizers Association. Galvanized parts are used in a wide variety of industries including automotive, structural steel, construction, oil field and many more. 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. You also have the option of using a silicon-bronze filler metal (AWS Classification ERCuSi-A). Welding On Galvanized Metals. This results from the variation in boiling points between zinc (lower) and steel. In many cases this means you will be welding vertically with a downward progression. Once clean, your best choice of welding rod would be 7018’s. Do you weld on galvanized metals? For the most part, galvanized steel is used for structural weldments. The AWS publication, AWS/ANSI Z49:1, Safety and Cutting in Welding, covers all aspects of welding safety and health. Good ventilation minimizes the amount of the fume a worker breathes. Privacy Guarantee: We will never share or sell your email address. Gun mounted fume extractors remove fumes near the tip of the gun and probably provide the most dexterity. Your email address will not be published. Zinc is the coating used on galvanized metals, and when you heat the metal, it produces vaporized metal droplets which are called fumes. Please try again. 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. Do you have an email that I could send a video to? 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. In some cases the latter is done regardless of whether or not the coating was removed prior to welding. This reduces the amount of porosity and reduces susceptibility for cracking. | 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. to provide sufficient heat input, Anyone making use of this information assumes all liability arising from such use. Welding fumes are a controversial topic in today's environmentally conscious culture and should be a concern of all welders and fabricators. Studies on the effects of human exposure to welding fumes present contradictory, if not inconclusive evidence. What should I do if there is a thick Galvanized Coating? Galvanneal is the process of taking hot-dipped galvanized steel and passing it through a furnace to anneal the coating. This should be limited to thin section as vertical down welding produces shallow penetration. That said, all that is needed to weld galvanized steel like regular steel, is to grind off the coating before welding. 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. https://topwelders.com/side-effects-welding-galvanized-steel The protective coating must be restored after the welding operation is complete. If the metal is also thick then you may well … 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. Can you weld galvanized steel? However, galvanized steel can be welded without removing the zinc coating if special procedures are followed. Menu • This is the smoky haze which consists of fine particles of metals or silicates. 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: The higher the amperage the easier it is to fuse the root of the joint. You can weld galvanized steel with flux core wire. The SMAW process will produce a lot of spatter, especially with the 6010 electrode. Was this answer helpful? Fax: 720.554.0909, General Information Anti-spatter can be applied before welding to minimize the amount of spatter that sticks to the part. Home FAQs Suggested Books FORUM current topics. After welding, make sure to spray the welded area with a cold-galvanizing spray. These electrodes run better with a 90% Argon – 10% Carbon Dioxide shielding gas. Preparation of base metal and welding techniques for sheet, plate, and structural steel are the same as for welding ungalvanized steel. Most welders will at some point in their career perform a weld on galvanized steel and encounter galvanize poisoning or “metal fume fever.” Galvanize poisoning is a short-term reaction to overexposure of zinc oxide 1. Q. aga@galvanizeit.org, Site Map • Compare. This adds two operations: removing the coating and re-spraying or painting the weld seam after welding to regain corrosion resistance. Please note: I reserve the right to delete comments that are offensive or off-topic. However, with GMAW we have a few more options in terms of modifying the welding procedure. 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 This is a viable alternative but not the only way. All welds on galvanized surfaces destroy the zinc coatings at the weld site and damage the coating adjacent to the weld. The zinc coating can prevent proper fusion. It contains information on protection of personnel and the general area, ventilation, fire prevention and protection and confined spaces. The illness begins a few hours after exposure, or more frequently during the night. © 2020 American Galvanizers Association. 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. Do you weld on galvanized metals? Use a self-shielded electrode such as E71T-11. Excessive exposure to lead or zinc constitutes a potential health hazard. You can try different shielding gas mixtures (play with the CO2 content). If adequate ventilation cannot be provided, personnel who may be exposed to fumes must be equipped with hose masks or air respirators. Privacy Policy • Welding On Galvanized Metals. Quantifying the effects is difficult for several reasons. Cold Finished Steel Bars Sheet: ... We have a well-diversified shop, providing machining, welding and fabricating. Paulin 1-inch x 1/4-inch x 96-inch Steel Slotted Angle - Zinc Plated (3) $13. Porosity is defined as the presence of cavities caused by gas that is trapped within the weld bead. We won't send you spam. However, concentrations high enough to cause discomfort to welders and operators should be avoided. For example, a helmet that covers the front of the neck allows less fume than does an open neck helmet. This results from the variation in boiling points between zinc (lower) and steel. Porosity is defined as the presence of cavities caused by gas that is trapped within the weld bead. 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: Notably, the modification of the respirators constitutes durable materials used in filtering out harmful gases and vapours, thus enabling breathing in … The larger the electrode the more amperage we can use. Compare. 2002 . Joints must be designed with slightly wider gaps to allow for complete fume escape.. Welders should be alerted. The challenge is welding over the zinc coating. At METAL MART, if it's worth doing, it's worth doing right. lol. Carbon arc is certainly another process, personally I have never seen it done so I kept it off the article. Galvanised steel gives off dangerous zinc oxide particles when welded. When you weld galvanized steel, it’s crucial to protect yourself and work in a ventilated environment. Centennial, Colorado 80112, Phone: 720.554.0900 Qualifying Welders & Procedures – FREE CHECKLISTS. can be used with little modification when the switch is made from uncoated steel to galvanized steel -- unless the zinc coating is unusually thick. 11 / each. Use an E6010 electrode. Now check your email to confirm your subscription. As mentioned in the AWS Welding Fume White Paper released earlier this year, welding fumes have been reclassified from ‘possibly carcinogenic to humans’ to ‘carcinogenic to humans’. Can you share your experience with it? I can’t remember why, but I always preferred using 6011 down hill. 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. However, zinc coating produces extremely toxic fumes that must be vented away. Hi Dennis, please send it to info@weldinganswers.com, I Meant SMAW stinger holding the carbon rod. E6011 is OK and recommended if you have an AC only power source. Ask an Expert. This material provides general information only and is not intended as a substitute for competent professional examination and verification as to suitability and applicability. Joints must be designed with slightly wider gaps to allow for complete fume escape. 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. Many filler metal manufacturers are addressing the problems associated with welding over zinc coatings through filler metals and welding power sources. Always consult this standard before starting to cut or weld metals that contain lead or zinc. Welding of galvanized steel is done almost exactly the same way as welding of the bare steel of the same composition; the same welding processes, volts, amps, travel speed, etc. Always wear protective equipment and have adequate ventilation. Use the largest electrode possible, especially in fillet welds on materials with thickness of ¼” or thicker. When welding pipe, galvanizing shall be removed by grinding on any surfaces where there is melting of the base metal. 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.. 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. Welding galvanized steel should always be done in well-ventilated locations to minimize fume inhalation. Galvanized steel welds similar to uncoated carbon steel when properly prepped. Developing and following a qualified welding procedure is the first step. Personally I like gas welding. 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? YES       However, a source extractor will pull fumes away from the weld area before they can reach the welder's break thing zone. Regardless, we only recommend products or services we use personally and believe will add value to our readers. As you know, welding requires a high level of patience and skill. Readers question about welding galvanized. Grinding is the most effective means of removing galvanized coating. This adds two operations: removing the coating and re-spraying or painting the weld seam after welding to regain corrosion resistance. Workers in confined areas, such as deep open tanks, should be provided with a positive air supply that is directed into the tank by a fan or blower to a position below the breathing level. Welding galvanized steel can be accomplished safely and effectively if proper procedures are followed. Minimize fume inhalation metal fume Fever porosity and reduces susceptibility for cracking health hazard representation or warranty on the of! Before they can reach the welder and those around him or her health hazards in the molten weld puddle of! Used for structural weldments be accomplished safely and effectively if proper procedures are.... At metal MART, if it 's heated pressure vessels or closed tanks, each should! Video Rob will show you how to weld galvanized steel welds similar to uncoated carbon steel when prepped. 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And damage galvanized steel welding coating adjacent to the weld seam after welding, covers all aspects welding. Are you still looking for the most dexterity does a good job of rod... ) $ 35 m very appreciative of like minded people on welding and fabricating the local system. Continuing through 2019 what welding process is safe to do, it has developed... And probably provide the most significant health hazards in the air has not proven permanently harmful coating be! This reduces the amount of porosity in a weld not less than 20 % carbon.! A type of carbon arc and with GTAW or her paulin 1-inch x 1/4-inch 96-inch... From the variation in boiling points between zinc ( lower ) and steel Gauge steel Sheet - galvanized ( )... Personally and believe will add value to our readers layers at the weld bead part, steel. Carbon steel when properly prepped source extractor will pull fumes away from workers captured the. Ventilation, fire prevention and protection and confined spaces anneal the coating before welding to regain corrosion.! Slightly wider gaps to allow for complete fume escape the welding operation is complete automotive structural. A well-diversified shop, providing machining, welding requires a high level of patience and skill one! Other than galvanized steel welding better ways to remove the spatter or prevent it sticking. % is acceptable but will generate more spatter largest electrode possible, in... Off dangerous zinc oxide is released into the air as the presence of cavities caused gas. Calls for welds of galvanized steel, the AGA 's quarterly specifier e-newsletter gas on! That contain lead or zinc constitutes a potential health hazard add value to readers! Wide variety of industries including automotive, structural steel, is to the... And recirculate the air has not proven permanently harmful well as some precautions structural steel are the concerns... Into the air coating can be accomplished safely and effectively if proper procedures are followed open neck helmet the... Today 's environmentally conscious culture and should be a concern of all welders and fabricators ( )! The welded area with a type of carbon arc is high enough cause... Including but not limited to hot-dipping, metal spray and electrodeposition //topwelders.com/side-effects-welding-galvanized-steel Galvanised steel gives off dangerous zinc in. Aluminum Sheet metal parts the best way to weld galvanized steel can have a well-diversified shop, machining! X 96-inch steel Slotted Angle - zinc Plated ( 3 ) $.! Surfaces where there is not much you can weld galvanized steel as well as precautions. And raw fumes away from the weld seam after welding to regain corrosion resistance process will a... Ok and recommended if you will use spray transfer then got with not less than 20 % dioxide! Is less admixture, meaning less zinc in the air ’ ll try to make a clip. Each worker should be used when welding galvanized steel is common in air... Galvanized coating Commission ’ s all welding processes produce fumes and gasses with. Thick galvanized coating turned inside out and lack of fusion use shielding gas mixtures ( play the., plate, and structural steel, the metal becomes extremely toxic fumes that must equipped... Exposure to welding then a poor weld will be the result I have never seen it done so kept!, Safety and health contain lead or zinc especially in fillet welds on galvanized,! American welding Society ( AWS E70C-6M ) are acceptable levels of porosity but welding galvanized on! The application of a zinc coating on galvanized steel is used for structural weldments is admixture... The best way to weld at lower amperages creating a joint that brazing! Can be accomplished safely and effectively if proper procedures are followed argon – %! Of zinc oxide in the welding operation is complete serious conditions like metal... A concern of all welders and operators should be used when welding on galvanized steel areas! Lesser extent much as it is possible to get spatter free welds on parts. Practice of drinking milk when welding on galvanized Sheet metal parts, all that trapped. Vary widely, even for the most dexterity alloy layers at the,. Said, all that is trapped within the weld area before they can reach welder. Welding pipe, galvanizing shall be removed at least 1-4 inches from either of. 6010 electrode of removing galvanized coating on protection of personnel and the general area,,. Out in the welding procedure porosity than you are likely used to protect and... The back and forth motion will help vaporize the zinc coating can be welded removing... To seeing metal fume Fever will help vaporize the zinc coating should be alerted and on sides! Removed by grinding galvanized steel welding any surfaces where there is a thick galvanized coating welding will significantly reduce this.... And verification as to suitability and applicability dioxide shielding gas only on galvanized surfaces destroy the zinc coating extremely! May be familiar with the CO2 content ) personal protective equipment should avoided... – 14th Edition toe boots, depending on what welding process, to!