Welding galvanized iron and rust

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Sorry if I'm out of place for asking this question because this forum looks like it's geared towards welders. But I searched online and couldn't find the specific answer so I'm glad to have found this forum.I am looking to have an iron rail installed on my new deck. It's going to be powder coated and my contractor told me not to worry about the rail rusting. Then the iron guy came out today and told me it will eventually rust, and in places where the rail is welded it will start showing sooner than later (within a year).So I told my contractor about this conversation and he suggested galvanized iron. That sounds good because it probably won't rust in my lifetime. But it will still have to be welded and I'm wondering if the points that are welded will be as rustproof as the rest of the rail or if these areas will be faster to rust? My contractor will probably tell me it won't rust but I'd feel better getting an informed answer from welders.Thank you!
Reply:Wouldn't you know it, minutes after registering here and starting this thread I found the answer to my question here.For the benefit of anyone who is searching for the answer to this question in the future and finds this thread, here is the answer.The heat from welding vaporizes the protective zinc coating near the weld. Even though the remaining zinc continues toprovide some protection to the zinc-free areas, the appearance is poor, and the zinc-free areas will rust when exposed to theenvironment.
Reply:Paint will not restore full galvanized protection, but there are other ways to restore a galvanized surface after welding.http://www.rotometals.com/product-p/regalvleadfree.htm.No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Working in marine construction most of my life, building bridges, and container ship docks. Some of the docks would be all galvanized steel. I would go for months welding galvanized steel. We used these rods to cover the weld area. 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:Originally Posted by CEPWorking in marine construction most of my life, building bridges, and container ship docks. Some of the docks would be all galvanized steel. I would go for months welding galvanized steel. We used these rods to cover the weld area.
Reply:go with a stainless steel railing.....
Reply:Originally Posted by Weld_can you describe the procedure a little bit.  So you're done welding now what?
Reply:Originally Posted by uscpsychoSorry if I'm out of place for asking this question because this forum looks like it's geared towards welders. But I searched online and couldn't find the specific answer so I'm glad to have found this forum.I am looking to have an iron rail installed on my new deck. It's going to be powder coated and my contractor told me not to worry about the rail rusting. Then the iron guy came out today and told me it will eventually rust, and in places where the rail is welded it will start showing sooner than later (within a year).So I told my contractor about this conversation and he suggested galvanized iron. That sounds good because it probably won't rust in my lifetime. But it will still have to be welded and I'm wondering if the points that are welded will be as rustproof as the rest of the rail or if these areas will be faster to rust? My contractor will probably tell me it won't rust but I'd feel better getting an informed answer from welders.Thank you!
Reply:Originally Posted by Weld_can you describe the procedure a little bit.  So you're done welding now what?
Reply:Thank you so much guys! Originally Posted by DSWPaint will not restore full galvanized protection, but there are other ways to restore a galvanized surface after welding.http://www.rotometals.com/product-p/regalvleadfree.htm
Reply:This is perhaps going a little off topic but since you guys work with metals you might be able to advise.I planned to use led lighting on my rail and mount it to the rail using anodized aluminum led channels. These channels would be screwed into the bottom of the rail (iron or galvanized iron). Where I screw the aluminum channel into the rail, is that going to weaken the rust protection at those points? If so, are there galvanized screws I could use or something else to prevent rust?And I've read that putting two different metals together can cause them to react in a way that weakens one or the other. Will I have that kind of reaction if I put anodized aluminum and iron or galvanized iron together?Last edited by uscpsycho; 04-28-2016 at 11:53 AM.
Reply:I would go with a quality paint job- if done correctly will last quite awhile and with regular maintenance , it's easy to keep the railing from becoming a rust bucket.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:Originally Posted by Broccoli1I would go with a quality paint job- if done correctly will last quite awhile and with regular maintenance , it's easy to keep the railing from becoming a rust bucket.
Reply:Originally Posted by uscpsychoSorry if I'm out of place for asking this question because this forum looks like it's geared towards welders. But I searched online and couldn't find the specific answer so I'm glad to have found this forum.I am looking to have an iron rail installed on my new deck. It's going to be powder coated and my contractor told me not to worry about the rail rusting. Then the iron guy came out today and told me it will eventually rust, and in places where the rail is welded it will start showing sooner than later (within a year).So I told my contractor about this conversation and he suggested galvanized iron. That sounds good because it probably won't rust in my lifetime. But it will still have to be welded and I'm wondering if the points that are welded will be as rustproof as the rest of the rail or if these areas will be faster to rust? My contractor will probably tell me it won't rust but I'd feel better getting an informed answer from welders.Thank you!
Reply:Originally Posted by Weld_can you describe the procedure a little bit.  So you're done welding now what?
Reply:Originally Posted by Birdhunter1He's a hobbyist!
Reply:Originally Posted by DSWIt's pretty much explained how to apply sticks like CEP posted in the video on the link I posted.https://www.youtube.com/watch?time_c...&v=yNAhjJ_scKc
Reply:Originally Posted by CEPI didn’t look at DSW’s video yet. What we did was power wire brush the weld area really good. Heat the area with a rose bud, and rub / melt the galvanized rods on the heated area. While the area is still somewhat hot, take a hand held wire brush and smooth it all out.
Reply:Originally Posted by Weld_there's always a clown in every circus  lol
Reply:Originally Posted by CEPBut I’ am!Here is a picture of the galvanized piling we drove at pier 69 downtown Seattle.  The piling get cut to grade. A 1” thick galvanized plate gets welded to the piling. Then galvanized beams get welded to the plate. Pre-cast concrete deck panels with embedded galvanized angle iron get welded to the beams. Now you can see why we used a rose bud to heat the weld area.