Welding Galvanized Steel

admin

I'm designing a trailer that I can attach to my bike so that I can carry my mower and other lawn care gear and I was planing on building the frame of it out of 1/2" electrical conduit but I'm having trouble finding the fittings that I need.  I've looked around and I've found people saying that you can and people saying that it will almost kill you due to the fumes produced.  Can I weld it if I wear some form of respirator while I'm doing so or would I just be better off using the fittings?  Also this is my first welding project so I apologize if any of this is clearly idiotic.
Reply:I spent years welding galvanized structural steel. Been poisoned a dozen or so times. It makes me sick as a dog over night, next morning like nothing ever happened. For me it starts off after dinner, like someone stuck an ice pick in one of my knees. Then it's like someone stuck a ice pick in one of my nuts! Then it's down hill from there, until the next morning.Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Easiest way is to sand off the galvy coating- it will weld so much better anyway.  It is not going to kill you.The Electrical tubing is really thin so yer gonna have a tough time as a first welding project. Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:I contend that there is not enough coating on conduit to affect you if you are in a open shop or outside. Second, if you are concerned about it then sand/grind off the coating to shiny steel and weld on...Sent from my iPhone using Tapatalk
Reply:I think some folk panic a little too much when it comes to galvanised metals, Yes it does make you ill if you breath it in, and you'll end up with Flu like symptoms, Possibly the shakes, But its almost gone in 48 hours.The secret is Local Exhaust Ventilation, If you've not got a Fume extractor then Use a normal Household Electric Fan to blow the fumes away from you, Better still weld it outside when theres a nice breeze, and position your head and shield so that the fumes don't go up inside the helmet,  and even better still wear a vented face mask like thisWelding Galvanised material is dangerous but the secret is minimizing the risks involved and if you've mastered that, you've cracked it
Reply:I just grind the coating off around the weld area and weld with a fan blow the fumes away from me
Reply:Second question I meant to ask in the original post.  Which would you all recommend for this, oxy acetylene, stick, or tig?  I have access to all three and I'm leaning towards stick but I've only cut metal, not weld it.
Reply:Conduit is gonna be kind of tough for a beginner with stick. You may consider sliding a short stub of solid round stock into the conduit. This will give you a fighting chance to weld it with stick.
Reply:Originally Posted by BD1Conduit is gonna be kind of tough for a beginner with stick. You may consider sliding a short stub of solid round stock into the conduit. This will give you a fighting chance to weld it with stick.
Reply:Originally Posted by pin2hotThe OP never stated if the conduit was EMT or rigid.  EMT would be a pain, at least it is for me.  I have a few things I've welded EMT for.  Rigid would be much easier.
Reply:I worked in a sheet metal shop for 3-years, we ran a lot of Silicon Bronze on galvanized sheet metal. Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Either EMT or rigid conduit can be easily welded with oxy/acet and r45 wire, or a coat hanger will do in a pinch.  I have made many things from both.  As long as you stay out of the smoke cloud you will do fine.  Oxy/acet is my preferred process with this material as you have more control with the heat input.  Fit-up is important.  Just my thoughts, hope it helps.   Bob
Reply:Grinding the coating off of the inside will still leave it on the inside.There are plenty of claims of it being lethal but OHSA is very clear that it is only a temporary illness just like CEP said.  If you want more information, google "osha welding galvanized metal" for the official OSHA view.
Reply:I found this wiki entry to be pretty informative.http://en.wikipedia.org/wiki/Metal_fume_fever
Reply:I have lost 40% of my lung function through welding fumes of various kinds including galvanised. I now struggle to walk up inclines. Don't treat galv. lightly or it will bite you eventually.Clive
Reply:Originally Posted by cliveI have lost 40% of my lung function through welding fumes of various kinds including galvanised. I now struggle to walk up inclines. Don't treat galv. lightly or it will bite you eventually.Clive
Reply:Why risk it? A half-mask respirator with 2097/2297 filters will only cost about 25 dollars. It may be overkill, but I would say it's better to err on the side of caution when it involves the health of your lungs. Breathing welding fumes is never a good thing.Sent from my iPhone using TapatalkAspiring Top-Notch WeldorLooking for work/experience in Eastern Massachussetts
Reply:Originally Posted by akatzWhy risk it? A half-mask respirator with 2097/2297 filters will only cost about 25 dollars. It may be overkill, but I would say it's better to err on the side of caution when it involves the health of your lungs. Breathing welding fumes is never a good thing.