Welding galvanized metal

[B_C]

I try to stay away from this stuff, but if you have to weld it what would be the best way,and how do you protect your lungs from the fumes?

BC

[84ZMike]

Acid will eat the galvo off.....or if you just have to weld it then keep you head out of the fumes and if at all possible hold your breath when welding it...some say drinking milk before hand will help....how much do you have to do at one time?...most of the stuff I run across it small pipe or bolts etc....with the little stuff I just stay out of the fumes and have at it....you can try grinding it off as well but it will still produce the fumes from grinding.... so now that I haven't answered your question good luck

[Tux_Rules]

From my experience (and from reading on the 'net), there really is no difference.
Quote from the PDF file:

Welding of Galvanized Products
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. can be used with little modification when the switch is made from
uncoated steel to galvanized steel -- unless the zinc coating is unusually thick.
The difference between welding galvanized steel and welding uncoated steel is a result of the low vaporization temperature of
the zinc coating. Zinc melts at about 900°F and vaporizes at about 1650°F. Since steel melts at approximately 2,750°F and
the welding arc temperature is 15,000 to 20,000°F, the zinc that is near the weld does not stand a chance -- it's vaporized!
By the time the weld pool freezes, the zinc is gone. This has two immediate consequences:
• The vaporized zinc increases the volume of welding smoke and fumes.
• The zinc at and near any welds is actually burned off by the heat of the arc, removing the protective zinc coating.

Try to grind/remove the galvo first, and as for the fumes, do try not to breathe them, but the worst that will happen is you will get sick:

HTML Version
PDF Version
From OSHA

There is a thread that kinda discusses it here:

Hobart Thread

[B_C]

I didn't see the post already on Galvanized welding but thanks for the come back...

BC

[Tux_Rules]

I didn't see the post already on Galvanized welding but thanks for the come back...

BC

The thread doesn't exactly discuss how to weld it, but it's close sorta-kinda-maybe
I was instructed (and from reading the PDF file in the link I provided) to grind/remove the galvanized coating off first as it melts so quick that on thin metal, it can create a never ending hole. It's no fun chasing a weld because it's the metal is melting faster than it can be filled (This is where my friend taught me to solder with 7018 while welding).

[hankj]

Don't breathe the s*#t, period.

Hank

[MichaelP]

A small exhaust would help. Something like a fan with a flexible hose to quickly remove the fumes.

[Grumpy]

. . . the worst that will happen is you will get sick:

And you wouldn't mind getting sick because??? If your going to weld galvanized do the right thing: keep head out of fumes and use a fan to help move the fume away from you. Don't get sick it's not worth it.

ps: Tux the best summer I ever had was in Indian Head, MI at some campground on the Indian River.

[professur]

I've taken to snorkeling. Took an old snorkel, duct taped on a hunk of hose, stuck the end down the back of my shirt, and breath in from the mouth, out through the nose. Takes a bit of practice to manage to inhale without pulling in nasally, but that's one of the benefits of allergy season. It ain't perfect, but for the small jobs it works well.

A word of advice. Don't try leaving the end of the hose loose. All kinds of nasty flying things get real curious about air currents into dark holes. If you want to remove it further than behind your own back, duct tape a clean gym sock over the end.

[Rocky D]

I've been welding a lot of galv building dog runs, fences and gates...you can see lots of it on my website...haven't been hit by it in many, many years...just stay out of the fumes...if you can taste it you been had. <<<Click Here>>>

[Broccoli1]

I've taken to snorkeling. Took an old snorkel, duct taped on a hunk of hose, stuck the end down the back of my shirt, and breath in from the mouth, out through the nose. Takes a bit of practice to manage to inhale without pulling in nasally, but that's one of the benefits of allergy season. It ain't perfect, but for the small jobs it works well.

A word of advice. Don't try leaving the end of the hose loose. All kinds of nasty flying things get real curious about air currents into dark holes. If you want to remove it further than behind your own back, duct tape a clean gym sock over the end.

God forbid ya rip one

[Rocky D]

ROFLGO...

[Tux_Rules]

And you wouldn't mind getting sick because??? If your going to weld galvanized do the right thing: keep head out of fumes and use a fan to help move the fume away from you. Don't get sick it's not worth it.

I certainly do agree to vent whenever possible, but made the comment as from reading some of the postings throughout the forum that welding galvonized is toxic and will kill ya if you breathe the fumes, which is simply not the case (though you most likely would wish you were dead if you breathe enough fumes ). After all, zinc is used in cold medicine (taken in proper doseage)

hankj
Don't breathe the s*#t, period.

Hank

Obviously the best advisable practice whenever possible.

Rocky D
just stay out of the fumes...if you can taste it you been had.

That was what I used for an indicator. When I take a drag off my cigarette and it starts tasting different, time to stop for the day.

[Sharp Tungsten]

The snorkel thing is a touch to Magiverish. Lets look at economics verse backyard engineering. Go to Lowes or LWS and buy a respirator with the proper cartridges for the tune of 30 or 45 dollars for a good comfortable respirator. A P-100 cartridge with charcoal lining will stop most of the fumes associated with welding fumes.

[Jonesy70]

When I weld Galvanized I put a fan next to my weld blowing AWAY from me...it is just a small box fan and it has enough draw to pull the fumes and smoke away from me...if I have to tig weld threw the crap, the fan will not adverse effects on the weld. Remember to weld it in as much of a open area as possible...if you can't...get fit for a resperator!!! Make sure that you do positive and negitive fit checks on it to make sure that you have the proper size...if it doesn't fit right, you might as well not wear it at all!!