Q&A for How to Weld Galvanized Steel

Your flame is either too high, too hot, or too close to the metal. You could also try using a different machine to see if that helps correct the problem.

A power grinder with a thick grinding wheel is more suited to this purpose. They retail for about $30 CAD and are a welder's best friend.

Hot-dip galvanization gives a thicker and uniform anti-corrosive surface layer after molten zinc immersion.

Your best bet in this case would be to turn your heat up on your welder; also check to see if your base metal has contaminants on it (rust, mill scale, oil/grease, dirt, etc.). Depending on what you are building, if you are welding thick enough metal, consider preheating, and make sure your machine is powerful enough to weld the thickness of steel you are welding.

It's likely due to carbon buildup because you didn't clean them with a wire brush. Brush the weld off until it's shiny after every time you run a bead.

Yes, galvanized steel can be welded. However, because of the galvanized zinc coating, the metal becomes extremely toxic whenever it's heated. 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. You'll also need to use an arc welder in order to properly join the steel together.

If you don't remove the galvanize coating from the steel when you weld it, it will produce a cloud of toxic smoke. If you aren't wearing the proper protective gear, exposure to the smoke can cause galvanize poisoning, which includes symptoms such as headache, nausea, dizziness, and fainting.

The noxious smoke produced whenever you weld galvanized steel can lead to galvanize poisoning, which includes symptoms such as severe nausea, headache, and dizziness. If you plan to weld galvanized steel, it's extremely important that you wear the proper safety equipment in order to limit your exposure.

It is highly recommended you use some form of respiratory protection, especially when welding galvanised steel. If your glasses fog up, consider using either different glasses or different respiratory protection to avoid this.

After welding, re-galvanize the area with an appropriate applicator (e.g. brush or spray). Most hardware and home DIY stores have spray cans and/or brush on materials in different quantities. This will ensure the untreated surface will protected from the weather. Apply a minimum of 2-3 coats while extending each additional coat beyond the last one. Make sure the surrounding areas are clean before applying it. You can also lightly scuff the surrounding areas with sandpaper (220-400 grit)) or a scuff pad to promote adhesion.

You should sand (120-220 grit) or grind down the immediate area to be welded and a bit on both sides. This will remove most of the galvanizing itself and will give you a ‘cleaner’ weld. Afterwards you can grind the weld down (if needed/desired) and re-apply the galvanized treatment with a brush or spray.