The galvanized zinc coating on the metal becomes extremely toxic when it is heated, making welding it a dangerous task.Proper safety precautions include wearing a welding mask, a good welding respirator, gloves and an apron.If you want to create a ventilation system, you need to grind off as much of the zinc coating as you can before you start.Since a MIG welder won't join the galvanized steel together, you'll need to use an Arc welder.While welding, work back and forth over the seam or opening and cover each area twice to join 2 surfaces together.
Step 1: Get a welder's mask, gloves, and apron.
When welded, galvanized steel is very toxic.It has a zinc coating that is very dangerous for humans to eat.You have to take precautions to avoid the fumes.Get a high-quality welding mask, a heavy-duty respirator, and a pair of welding gloves.To keep sparks from ruining your clothing, wear a welding apron.It's a good idea to get a respirator that is specifically designed for welding metal.A standard dust mask won't work.Before welding galvanized steel, some welders recommend drinking a glass of milk or taking a calcium supplement.The zinc fumes can be counteracted by the calcium.
Step 2: Next to your welding site, set up a fan or a fume extractor.
If you are setting up in a workshop or job site, it is advisable to set up a fume extractor 2–3 feet away from the exact location where you're welding to absorb the fumes immediately.You can blow the zinc fumes away from you if you set up as many fans as you can behind you.If you can, Weld outside.If you can, open as many windows as possible.If you can't open windows, look for other ways to breathe in the room.You can't use galvanized steel in a closed room.A heavy-duty vacuum is used to suck up fumes.If you don't have one, you can rent one from a building supplies store or contractor.
Step 3: Place the claw over the work surface to ground the welder.
Welders need to be grounded to prevent shocks.The welder needs to be grounded if it is similar to the jumper cables for a car.To ground the object, open the grips and release them.You can either use a piece of metal or the work surface.If you are working outside, ground the object itself.Even though you shouldn't be touching the object that you're welding to begin with, there's a good chance you will get cut.You need to take precautions to stay safe at work.
Step 4: You need to grind away the zinc coating at the site where you are welding.
Put on your protective gear.Wear away the zinc coating with a sheet of 220-grit sandpaper or a grinder.If you are dealing with a thin galvanized coating and using appropriate rods, this isn't important.It will increase the chances that you are not exposed to harmful fumes.If you want to strip smaller materials, like galvanized bolts or strips, you can soak them in a cup of vinegar.While welding galvanized steel, grinding or sanding won't release toxic fumes.
Step 5: You can either place your 2 pieces together or isolated your repair.
Put 2 pieces of galvanized metal on your work surface and arrange them in a way that you want them to set.You don't need to hold the pieces together.If you are welding a hole or tear to close it off, set your piece down on your work surface so that the opening is facing up.If you have to lay your pieces out on the floor, make sure that you are welding on a non-combustible surface.
Step 6: If you can, place smaller pieces with a welder.
If you want to make a perfect seam, you need to force the sheets together with a welder.Iron or metal welding clamps are used.Place the 2 pieces in between the ends of the clamps.The frame should be held still while you turn the dial at the end clockwise.C-clamps are often referred to as welding clamps.You can get away with using any metal clamps if they aren't marketed as welding clamps.You can't use plastic to hold objects together.
Step 7: To make galvanized steel, use an welder.
The best way to work with galvanized steel is with a standard welder.Arc welding uses alternating currents to create high-heat arcs that melt your flux.When using an Arc welder, you should be able to work outside.There is occasional spatter from the arcs.If you only have one welder in your workshop, you should use an Arc welder.Most people think that it is the easiest welder to use.
Step 8: You can choose the size of your welding rod.
If your welder works with a welding rod of any size, you can use it.A bigger rod is going to weld a bigger area than a smaller rod.There are no galvanized steel-specific tools that you need.You can use a 6013, 7018, 6011, or 6010 welding rod.The most common rods should be easy to find.
Step 9: If you are joining 2 pieces, start on one end of the seam.
If you are welding 2 pieces of steel together, start on one end of the seam.After starting the power, place the welding rod 1–2 inches away from the beginning of the seam and press the button.There will be sparks when you start welding.Do your best to keep the welding rod in place.If you are wearing the proper safety materials, you will be fine.
Step 10: If you want to apply your welding flux, you have to heat it.
Move your welding rod down the seam 2–3 inches at a time.Work your way back over the area that you just welded, slowly.After covering a surface twice, move on to the next part of the seam.For the entire length of the gap, repeat this process.Wait for at least 15 minutes to let the welding flux settle before trying to test the bond or sand it down.
Step 11: Attach a Weld around the edge of the tear.
Start welding on the edge of the metal.Work slowly around the exterior edge of the metal, moving forward 2–3 inches (5.1– 7.6 cm) before bringing your welding rod back over the surface you just covered.Continue this process until you have worked all the way around the outside of the cut or split, then move in towards the center.Until the entire hole is covered, do this.If the gap in the center is more than 1 in, you can't use split or tear shut.Over time, the welding material won't stay closed.Wait 15-20 minutes to make sure the welding flux is on the safe side.If you want, you can paint the area.