Having problems with galvanized steel

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I'm a newbie welder - am using a second hand (old...) arc (stick) welder. AC, using 6013 sticks. Am working at about 90 amps. I'm trying to put together a balcony using - 20mm hollow square profile galvanized steel- 5x20mm galvanized steel strips- 8mm square profile mild steel I'm having real problems with the galvanized steel strips. I can get a fair weld on the square profile - even without grinding off the galvanizing. No problems on the mild steel. The galvanized steel strips, however, are a pain - I am trying to weld joints between them and the other two, yet the bead is usually poorly attached to the steel strip. I used an angle grinder to prepare the surface, which did not seem to help. The steel strip seems to be differently galvanised to the square profile - it's a rough, shiny coating as opposed to the square profile's smooth, dull coating.Should I be grinding deeper and wider ? Would be glad to hear any ideas...D. Attached ImagesLast edited by dand99; 07-27-2011 at 02:41 PM.
Reply:http://www.sperkoengineering.com/htm...Galvanized.pdfEd 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:Thanks - have seen that, but doesn't really solve my problem...
Reply:In the little instruction I got in welding from the friend I bought my welder from... he said galvanization could not be ground off... had to be burned off... he might not have been speaking technically... but when I have to deal with it .. I use the OA torch on it ... making sure I am standing UPwind.... He might have meant that it is deep enough in the pores that if you actually ground it off you would not have enough good metal left to work with...Weldandpower Lincoln 225 AC,DC with Briggs 16hp gas engine.WW2 era Miller TIG.
Reply:Whaada ya mean you can't grind it off..All it is is a coating..I do it whenever I have to weld any of that crap..Burn it off?That's a new one.......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:On thick stuff I am sure it can be ground  off.... but on thin stuff...like corrugated roofing..... try it sometime...Nice smokey yellow green residue.... remember.... upwind and outdoors if you can.....Last edited by GBM; 07-27-2011 at 04:45 PM.Weldandpower Lincoln 225 AC,DC with Briggs 16hp gas engine.WW2 era Miller TIG.
Reply:For a balcony I would want something with a lot deeper penetration than 6013.I'd be using 6011.
Reply:Another vote for 6011.
Reply:I vote for not having people, who don't know how to weld, working on a damn balcony...
Reply:Good point..That should be a given.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Originally Posted by jmtebbensI vote for not having people, who don't know how to weld, working on a damn balcony...
Reply:After I get this balcony done I'm going to biuld an elavator Out of a mountan bike and old chain saw.
Reply:It's rather disappointing to see a host of sarcastic comments rather than advice, which is what I would (perhaps optimistically) expect as a newbie. The load bearing parts of the balcony are held by nuts and bolts (as you might have seen from the picture). The welds are mainly to lock the joints in place. As to 6011, I'll look for some....Last edited by dand99; 07-28-2011 at 01:04 AM.
Reply:wow guys, i'm pretty sure the first time you picked up a stinger you weren't the top dog welder either. I agree with someone not knowing how to weld not working on something like a balcony, but at least try to point him in the right direction.
Reply:Claymans,The "right direction" is away from the balcony and into a classroom.  There is no two ways about it.What does "lock the joints together" mean?  You mean like lock washers or nylock nuts?  You don't use a welder, which will change the metallurgical structure, on something that holds people lives just to stiffen something up.  That's what pins and more bolts are for.I want to see a bigger picture of this balcony to see what the heck is going on...
Reply:Dan, you're dealing with two different processes vs the galvanized steel.  One (the strips) is hot dip galvanized and the other parts are electro-galvanized.  Hot dip usually gives a much thicker coating and is much more difficult to grind off without getting into the parent metal pretty good.  And you cannot "burn off" hot dip galvanize.  If it's thick enough parent metal you can sometimes burn through it but that's not a bright idea.It's apparent to me (from what I can see) you're aim is just to tie things together with the welds and the fasteners are what's actually holding everything together.  IF that's the case then the 6013 rods are good enough.  6011 may give you issues with such thin metal unless you've got a lot of experience with it.Unfortunately it's sometimes hard to get any advice on this board because some of the members seem to get great satisfaction from being overly harsh with their criticism and berating any "newbie" that doesn't posses the skills they do.  Some think they know the "only way" to do something is the way they would or can do it.  To them every weld should look like a text book picture and anything less is crap.  Which is somewhat true...LOL.Arrogance is not a trait that's lacking on this board.  None of these guys was born with a stick holder in his hand.  Not everyone is a professional welder nor do they want to be.  I've been in this business over 30yrs and we've had some "special" welders.... guys that were fantastic in every way but one.  They couldn't get along with anyone because they were so full of themselves.  We almost always ended up showing them the door.  Those guys end up working by themselves which is really where most of them are happy.Some of them hang out here....:-)
Reply:Few additional things:1. welding galv can release toxic fumes.  Use an appropriately rated respirator.2. Yes, those are two different processes, hot dipped vs. electro, one is a heck of a lot thicker than the other.3. In order to get a clean and proper weld, the galv needs to be ground off...yes, ground, not burned4. Show us some pictures of your welds so you can get advise as to whether or not you are skilled and experienced enough to weld on something like a balcony5. Unless an engineer has looked at the design, materials, etc... you are using on the balcony...then stop and have an engineer review the design6. If the welds you show don't get a thumbs up as quality enough for something as dangerous as a balcony, then take that to heart and stop...get more experience and when you're good enough go back to building balconies but with the appropriate engineering review and sign off on the design and materials.--Wintermute"No man's knowledge here can go beyond his experience." - John Lockewww.improvised-engineering.comManufacturer Agnostic:Blood----------Sweat---------Tears----|------------------|----------------|----Lincoln Red, Miller Blue, Esab Yellow
Reply:Thanks - exactly what I was looking for....Now I know I have I have a problem which I probably cannot work around with the hot dipped strips - saves me some pointless grinding, though...  The welds do eventually stick to the strips - requires much more time and patience, though...D.  Originally Posted by kaferhausDan, you're dealing with two different processes vs the galvanized steel.  One (the strips) is hot dip galvanized and the other parts are electro-galvanized.  Hot dip usually gives a much thicker coating and is much more difficult to grind off without getting into the parent metal pretty good.  And you cannot "burn off" hot dip galvanize.  If it's thick enough parent metal you can sometimes burn through it but that's not a bright idea.It's apparent to me (from what I can see) you're aim is just to tie things together with the welds and the fasteners are what's actually holding everything together.  IF that's the case then the 6013 rods are good enough.  6011 may give you issues with such thin metal unless you've got a lot of experience with it.Unfortunately it's sometimes hard to get any advice on this board because some of the members seem to get great satisfaction from being overly harsh with their criticism and berating any "newbie" that doesn't posses the skills they do.  Some think they know the "only way" to do something is the way they would or can do it.  To them every weld should look like a text book picture and anything less is crap.  Which is somewhat true...LOL.Arrogance is not a trait that's lacking on this board.  None of these guys was born with a stick holder in his hand.  Not everyone is a professional welder nor do they want to be.  I've been in this business over 30yrs and we've had some "special" welders.... guys that were fantastic in every way but one.  They couldn't get along with anyone because they were so full of themselves.  We almost always ended up showing them the door.  Those guys end up working by themselves which is really where most of them are happy.Some of them hang out here....:-)
Reply:Originally Posted by kaferhausArrogance is not a trait that's lacking on this board.  None of these guys was born with a stick holder in his hand.  Not everyone is a professional welder nor do they want to be.  I've been in this business over 30yrs and we've had some "special" welders.... guys that were fantastic in every way but one.  They couldn't get along with anyone because they were so full of themselves.  We almost always ended up showing them the door.  Those guys end up working by themselves which is really where most of them are happy.Some of them hang out here....:-)
Reply:I don't even grind it, burn it away with 6010, and cover with 7018. Then again, it's usually just legs I'm welding on a stand for some piece of equipment at work. I do drink milk beforehand as well.As far as hostile responses, not singling out anybody or anything, just saying...some people may need to grow skin. If a co-worker is overboard with with an answer, I just assume their really trying to drive home a point, I take nothing personal, and hope others take my elevated voice patterns the same as well...Alot of guys here truly want others to "get it" or do it right, Zap, Duanne and a few others are pretty good examples. They willingly share their knowledge with total strangers and offer thoughts and remedies on a daily basis. So please stay put on WW as their s a ton of info, that has taken many careers to achieve...Have fun with the project, and post pics as well. Constructive criticisms are often had in between the hostile posts..Lincoln Power MIG 210 MP ( boat anchor )Lincoln Weld-Pac 100 HDHobart IronMan 230Cutmaster 42Jackson NexGenSumner Ultra ClampsDWM120