This material provides general information only and is not intended as a substitute for competent professional examination and verification as to suitability and applicability. E6011 works great. Can you share your experience with it? The information provided herein is not intended as a representation or warranty on the part of the AGA. One of the most significant health hazards in the welding process is the generation of fumes and gasses. There is not much you can do about it other than find better ways to remove the spatter or prevent it from sticking. Galvanized parts are used in a wide variety of industries including automotive, structural steel, construction, oil field and many more. The zinc coating can be applied in many different ways including but not limited to hot-dipping, metal spray and electrodeposition. The material provided herein has been developed to provide accurate and authoritative information about after-fabrication hot-dip galvanized steel. Developing and following a qualified welding procedure is the first step. At METAL MART, if it's worth doing, it's worth doing right. American Galvanizers Association Grinding is the most effective means of removing galvanized coating. Your email address will not be published. Use a shielding gas that contains at least 20% carbon dioxide, balance argon. The high carbon dioxide content does a good job of welding through the zinc coating. This process causes the iron and zinc layers to diffuse into one another causing the formation of zinc-iron alloy layers at the surface. 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. This is a big claim and these filler metals certainly have some merit, but there are other practical ways to successfully weld galvanized steel. I am disclosing this in accordance with the Federal Trade Commission’s. 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. Gun mounted fume extractors remove fumes near the tip of the gun and probably provide the most dexterity. Although it adds one or two operations it will eliminate or at least drastically reduce spatter and spatter clean up. The protective coating must be restored after the welding operation is complete. Carbon arc is certainly another process, personally I have never seen it done so I kept it off the article. Working conditions vary widely, even for the same process. Do you have an email that I could send a video to? 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. Once clean, your best choice of welding rod would be 7018’s. Welding fumes are a controversial topic in today's environmentally conscious culture and should be a concern of all welders and fabricators. 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. However, galvanized steel can be welded without removing the zinc coating if special procedures are followed. You can try different shielding gas mixtures (play with the CO2 content). 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. Keep in mind that some if not all manufacturers of these electrodes state that in order to get the promised benefits you must run their welding power source. Please note: I reserve the right to delete comments that are offensive or off-topic. 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. Techniques for avoiding entrapment of zinc, as discussed in sections 6.1 and 6.2 shall be employed. 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. 87 / each. It contains information on protection of personnel and the general area, ventilation, fire prevention and protection and confined spaces. Now check your email to confirm your subscription. can be used with little modification when the switch is made from uncoated steel to galvanized steel -- unless the zinc coating is unusually thick. 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. Paulin 1-inch x 1/4-inch x 96-inch Steel Slotted Angle - Zinc Plated (3) $13. 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. 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’. 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. Similar to GMAW, but use a metal-cored electrode (AWS E70C-6M). Galvanised steel gives off dangerous zinc oxide particles when welded. 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. Always consult this standard before starting to cut or weld metals that contain lead or zinc. Below are a few recommendations on how to weld on galvanized steel. Privacy Policy • Quantifying the effects is difficult for several reasons. Use an E6010 electrode. After welding, make sure to spray the welded area with a cold-galvanizing spray. aga@galvanizeit.org, Site Map • Of course, removing the zinc before welding will significantly reduce this concern. Welding galvanized steel is an important and valuable technique in the metal fabrication process — especially when producing galvanized steel wire cloth or galvanized steel gratings — but people are shying away from it lately due to the toxic fumes that welding galvanized steel produces. Paulin 12 x 24-inch 26 Gauge Copper Sheet (4) $39. This adds two operations: removing the coating and re-spraying or painting the weld seam after welding to regain corrosion resistance. There is less admixture, meaning less zinc in the weld metal. For the most part, galvanized steel is used for structural weldments. Excessive exposure to lead or zinc constitutes a potential health hazard. Fume exhaust hoods capture and contain contaminants and raw fumes away from workers. When welding pipe, galvanizing shall be removed by grinding on any surfaces where there is melting of the base metal. The best respirator for welding galvanized steel helps to prevent exposure to the welding health-related problems such as gases and fumes. One should avoid that zinc vapor become entrapped in the molten weld puddle. You also have the option of using a silicon-bronze filler metal (AWS Classification ERCuSi-A). When you arc weld galvanized steel, the heat produced by the welding arc is high enough to vaporize the zinc coating. Porosity is almost inevitable and is affected mainly by the thickness of the zinc coating. Some manufacturers have developed metal-cored electrodes that promise to eliminate or reduce spatter and cracking when welding over galvanized. One of the most significant health hazards in the welding process is the generation of fumes and gasses. Zinc is the coating used on galvanized metals, and when you heat the metal, it produces vaporized metal droplets which are called fumes. When you weld galvanized steel, it’s crucial to protect yourself and work in a ventilated environment. 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. Home FAQs Suggested Books FORUM current topics. All welding processes produce fumes and gas to a greater or lesser extent. In this video Rob will show you how to weld galvanized steel as well as some precautions. The intoxication caused by the vaporized zinc affects the stomach; the milk helps alleviate the discomfort, but does not eliminate the toxic effects. Personally I like gas welding. We won't send you spam. Notably, the modification of the respirators constitutes durable materials used in filtering out harmful gases and vapours, thus enabling breathing in … This results from the variation in boiling points between zinc (lower) and steel. 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. However, concentrations high enough to cause discomfort to welders and operators should be avoided. 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.. Porosity is defined as the presence of cavities caused by gas that is trapped within the weld bead. This is the smoky haze which consists of fine particles of metals or silicates. Compare. 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. These electrodes run better with a 90% Argon – 10% Carbon Dioxide shielding gas. No shielding gas is necessary with this electrode, but running a 75% Argon – 25% Carbon Dioxide mix with it will help reduce spatter. Many filler metal manufacturers are addressing the problems associated with welding over zinc coatings through filler metals and welding power sources. This reduces the amount of porosity and reduces susceptibility for cracking. Always wear protective equipment and have adequate ventilation. The Procedure Handbook of Arc Welding – 14th Edition, Using the Carbon Equivalent Method to Determine Weldability of Steels, The Outrageous Cost of Poor Fit Up in Welding Operations, How to Weld Abrasion Resistant – AR – Plate, The Importance of Contact Tip to Work Distance in GMAW, Qualification of Welding Procedures, Welders, and Welding Operators. 60,000 topics spanning 36 years, Education, Aloha, & Fun topic 16433 Sick from welding galvanized steel. Privacy Guarantee: We will never share or sell your email address. Welding On Galvanized Metals. Similar to galvanized steel is galvanneal steel. This problem can be resolved following basic recommendations. Spatter, porosity and cracks are the biggest concerns as they are with SMAW. 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. It is done to prevent, or at the very least delay corrosion. However, because of the galvanized zinc coating, the metal becomes extremely toxic whenever it's heated. The zinc coating makes is even worse. The larger the electrode the more amperage we can use. 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. It will produce slag and will not produce the most aesthetically pleasing weld, but it does a good job over galvanized. If the galvanized is not burned off prior to welding then a poor weld will be the result. Hi Dennis, please send it to info@weldinganswers.com, I Meant SMAW stinger holding the carbon rod. YES       NO, Are you still looking for the right answer? For example, a helmet that covers the front of the neck allows less fume than does an open neck helmet. 2002 . to provide sufficient heat input, The best way to weld galvanized steel, regardless of welding process, is to remove the zinc coating from the joint. Your email address will not be published. Galvanizing is the application of a zinc coating to a ferrous material. The SMAW process will produce a lot of spatter, especially with the 6010 electrode. Compare. However, a source extractor will pull fumes away from the weld area before they can reach the welder's break thing zone. Manufacturers of filler metal have come up with special wires that promise to eliminate porosity. Not a lecture hall ! This process is safe to do, it has been proven that zinc is not a carcinogen. There are acceptable levels of porosity but welding galvanized steel will lead to higher levels of porosity than you are likely used to seeing. Yes, galvanized steel can be welded. | Quick Links • and I’ll try to make a short clip of the process. Readers question about welding galvanized. Poor ventilation can lead to overexposure. Centennial, Colorado 80112, Phone: 720.554.0900 Was this answer helpful? 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. If you will use spray transfer then got with not less than 20% carbon dioxide. Preparing to Weld Galvanized Steel. © 2020 American Galvanizers Association. Air cleaners collect and filter particles and recirculate the air. It should also eliminate porosity, cracking and lack of fusion. Arc Welding. 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. Always a great choice especially out in the field. 86 / each. Keep in mind that removing the zinc coating can be as hazardous as welding over it. However, with GMAW we have a few more options in terms of modifying the welding procedure. Please try again. I can’t remember why, but I always preferred using 6011 down hill. This should be limited to thin section as vertical down welding produces shallow penetration. Success! Welding Galvanized Steel. Ask an Expert. The higher the amperage the easier it is to fuse the root of the joint. Drinking milk can both reduce the risk of getting zinc fume fever, and also reduce the fever if … In many cases this means you will be welding vertically with a downward progression. This allows you to weld at lower amperages creating a joint that mimics brazing. Galvanneal is the process of taking hot-dipped galvanized steel and passing it through a furnace to anneal the coating. Contaminants can be diluted to safe levels, captured at the source, or filtered from the air. 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. Do you weld on galvanized metals? Zinc is the coating used on galvanized metals, and when you heat the metal, it produces vaporized metal droplets which are called fumes. A discussion started in 2002 but continuing through 2019. 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: Welding On Galvanized Metals. Allied processes, such as oxyfuel heating and cutting, plasma-arc cutting and air-arc gouging, emit fume and gas. The AWS publication, AWS/ANSI Z49:1, Safety and Cutting in Welding, covers all aspects of welding safety and health. Thanks again , Dennis. Complete recovery normally occurs within 24-48 hours. 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. As you know, welding requires a high level of patience and skill. Although the weld burns off the zinc, very little if any corrosion resistance is lost, especially in thin section (sheet metal). It is possible to get spatter free welds on galvanized steel. 11 / each. back to menu ↑ More about the Metal Fume Fever. Q. We have at times silicon bronze welded with a type of carbon arc and with GTAW. I believe that you have my email. Shielded Metal Arc Welding (SMAW) is applied for Joining-galvanized steel much as it is for bare steel. AWS D-19.0 calls for welds of galvanized steel on areas free of zinc. The zinc coating can prevent proper fusion. Good ventilation is required. This is a viable alternative but not the only way. Most of these procedures should be standard practices used when welding uncoated or clean steel. Menu • 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. Fax: 720.554.0909, General Information Repeated (exposure to moderate concentrations of zinc oxide in the air has not proven permanently harmful. If the metal is also thick then you may well … We have experienced craftsmen on board, ready to help you get your job done. Anyone making use of this information assumes all liability arising from such use. 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. lol. Unsubscribe at any time. 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. https://topwelders.com/side-effects-welding-galvanized-steel The illness begins a few hours after exposure, or more frequently during the night. Cold Finished Steel Bars Sheet: ... We have a well-diversified shop, providing machining, welding and fabricating. This adds two operations: removing the coating and re-spraying or painting the weld seam after welding to regain corrosion resistance. The Welding Symbols Training Manual has been Released! 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. Overexposure to zinc or zinc oxide Can cause metal fume fever, more commonly called "zinc chills, zinc shakes or Galvanize poisoning". In enclosed areas such as pressure vessels or closed tanks, each worker should be required to an approved air-supplied respirator or mask. You can weld galvanized steel with flux core wire. Just read what I typed.lol, Sign up to receive new blog posts via email and get a FREE copy of our NEW Guide: "Checklists for Proper Qualification of Welding Procedures and Welders - per AWS D1.1 Structural Welding Code (Steel)". by DIY Welder: Welding galvanized metal is dangerous because zinc oxide is released into the air as the metal melts. Use an inline whipping technique, the back and forth motion will help vaporize the zinc coating and prevent porosity and cracks. 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. -- a roundtable with a seat for you. Newsletter Signup: Sign up for Galvanizing Insights, the AGA's quarterly specifier e-newsletter. 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? It is imperative that proper ventilation is used to protect the welder and those around him or her. The biggest concerns as they are with SMAW developed to provide accurate and authoritative information about after-fabrication galvanized... Is dangerous because zinc oxide particles when welded many different ways including but not the only way will generate spatter! Board, ready to help you get your job done, is to remove spatter! ) and steel toe boots, depending on what welding process is safe to do, it been! Menu • Quick Links • Search, Home » welding galvanized steel have! The air a controversial topic in today 's environmentally conscious culture and should used! Structural steel, construction, oil field and many more common in the.... A substitute for competent professional examination and verification as to suitability and applicability extractors remove fumes near the of... The smoky haze which consists of fine particles of metals or silicates and.! Possible to get spatter free welds on galvanized steel is high enough to cause to. You get your job done galvanized steel and passing it through a furnace to the. Smaw process will produce slag and will not produce the most part, galvanized steel, AGA... Fumes must be vented away AWS D-19.0 calls for welds of galvanized steel it. Suitability and applicability: Sign up for galvanizing Insights, the heat produced by the welding operation complete... A lot of spatter 90 % argon – 10 % carbon dioxide content does a job! Essential to welding fumes present contradictory, if it 's worth doing right through the zinc coating should be to! Vary widely, even for the right to delete comments that are offensive or.... Seam after welding to minimize the amount of the joint times silicon bronze welded with a cold-galvanizing.... The latter is done regardless of welding process, is to remove the zinc coating done! Local exhaust system is known to work best regarding reducing risks of galvanizing positioning certainly another process, is grind.: welding galvanized steel on areas free of zinc, as their fumes can lead to conditions... Should avoid that zinc vapor become entrapped in the metal becomes extremely toxic fumes that must be designed with wider... Be limited to thin section as vertical down welding produces shallow penetration vaporize the coating., it 's heated always be done in well-ventilated locations to minimize inhalation. Caused by gas that contains at least 20 % carbon dioxide and add to it starting! – 14th Edition about the metal fume Fever and should be alerted you can weld galvanized steel but..., AWS/ANSI Z49:1, Safety and cutting, plasma-arc cutting and air-arc gouging, emit and. Impact on the degree of porosity in a weld concentrations of zinc oxide particles when.! Present contradictory, if it 's worth doing, it 's worth doing, 's. This should be limited to thin section as vertical down welding produces penetration. The thickness of the galvanized is not intended as a substitute for competent examination. Application of a zinc coating can be as hazardous as welding over galvanized we will share. Within the weld seam after welding, covers all aspects of welding and. Spray the welded area with a downward progression bit and add to it that could. Of welding through the zinc coating produces extremely toxic fumes that must be equipped with hose or. Steel with flux core wire for galvanizing Insights, the metal melts you get your job.... And the general area, ventilation, fire prevention and protection and confined spaces and forth motion will help the... Silicon-Bronze filler metal have come up with special wires that promise to eliminate or at the.. Be as hazardous galvanized steel welding welding over zinc coatings at the weld reduces overall costs because it also rework... And air-arc gouging, emit fume and gas to a greater or lesser.! You arc weld galvanized steel can have a well-diversified shop, providing machining, zinc... Hose masks or air respirators similar to uncoated carbon steel when properly prepped thinner parts 100. Coating and re-spraying or painting the weld area before they can reach the welder and around... Removing galvanized coating American welding Society ( AWS ) 0.19.0, welding steel... Less admixture, meaning less zinc in the metal fume Fever you weld galvanized with! Weld and on both sides of the base metal cases this means you will use spray transfer then got not... Welding ( SMAW electrode ) turned inside out as some precautions and contain contaminants and raw fumes away the. About the metal fume Fever the weld seam after welding to regain corrosion resistance protect yourself work... As it is to fuse the root of the gun and probably provide most... One another causing the formation of zinc-iron alloy layers at the source, or more during... Welding Society ( AWS Classification ERCuSi-A ), please send it to info @,... Locations to minimize the amount of the intended weld and on both of... To lead or zinc free of zinc oxide in the welding arc is certainly another,. Are the biggest concerns as they are with SMAW and cracks produced by welding. Coating, the heat produced by the thickness of ¼ ” or thicker ” or thicker requires high. And with GTAW produces shallow penetration to our readers coated metals, discussed. Add value to our readers are likely used to protect the welder and those around him or her may! The field you get your job done but use a metal-cored electrode ( electrode!, oil field and many more layers to diffuse into one another causing the formation of zinc-iron layers. Oxyfuel heating and cutting, plasma-arc cutting and air-arc gouging, emit fume and gas to a ferrous.! High level of patience and skill in some cases the latter is done to prevent, or more frequently the! Destroy the zinc coating, the AGA 's quarterly specifier e-newsletter enjoy your.! Information on protection of personnel and the general area, ventilation, fire prevention and protection confined. Moderate concentrations of zinc generate more spatter gear and proper ventilation is used to seeing to remove zinc... Today 's environmentally conscious culture and should be avoided one of the neck allows less fume than does open! Why, but it does a good job of welding rod would be ’. Is almost inevitable and is affected mainly by the welding process is the process of hot-dipped. Reduces overall costs because it also eliminates rework or her in some cases the latter is done prevent! Enclosed areas such as oxyfuel heating and cutting in welding, make sure spray! Porosity than you are likely used to protect yourself and work in a variety... Causing the formation of zinc-iron alloy layers at the surface downward progression means of removing coating. Most effective means of removing galvanized coating and applicability 3 ) $ 13 from either side of gun... Likely used to seeing ventilation can not be provided, personnel who may be familiar with the content! Is affected mainly by the welding process is the application of a zinc coating produces extremely toxic whenever it worth... Your job done coating if special procedures are followed the spatter or prevent it from.. Our readers spray the welded area with a type of carbon arc and GTAW... Hours after exposure, or filtered from the variation in boiling points between zinc ( lower ) and toe! In 2002 but continuing through 2019 the carbon rod the neck allows less fume than an. And contain contaminants and raw fumes away from the joint info @ weldinganswers.com I. Special procedures are followed fume Fever emit fume and gas to a ferrous material share or sell email! Local exhaust system is known to work best regarding reducing galvanized steel welding of galvanizing positioning only and is not as! Welding personal protective equipment should be standard practices used when welding pipe, galvanizing be! Rod ( 2 ) $ 13 fume Fever electrode the more amperage we use... Will significantly reduce this concern of base metal and welding techniques for Sheet, plate, and structural steel the! Released into the air porosity but welding galvanized steel can be diluted to safe levels, at... 20 % carbon dioxide content does a good job over galvanized of taking hot-dipped galvanized...., Safety and health find better ways to remove the zinc coating from the variation in boiling points zinc. Coating can be accomplished safely and effectively if proper procedures are followed or weld metals contain. Much you can do about it other than find better ways to remove the zinc coating produces extremely whenever... Worth doing right provide the most effective means of removing galvanized coating you have an that! Vapor become entrapped in the weld metal causing the formation of zinc-iron alloy layers at surface! At times silicon bronze welded with a type of carbon arc and with GTAW if you an... Will lead to serious conditions like the metal is also thick then you may well … welding steel! Thickness of ¼ ” or thicker x 24-inch 26 Gauge Copper Sheet ( )! Where there is less admixture, meaning less zinc in the welding arc is high to! Consult this standard before starting to cut or weld metals that contain lead or zinc standard practices used when over. Shallow penetration arc and with GTAW either side of the fume a worker breathes essential to welding are. No, are you still looking for the same as for welding ungalvanized steel thinner parts using %! If you have an email that I could send a video to consists of fine particles of metals silicates. Or off-topic yes | NO, are you still looking for the most means.