Technical Info Sheet #6

WELDING AFTER GALVANIZING

Points to consider when welding galvanized steel

When designing large or intricate structures, it is best to assume straight, loose profiles that can be subsequently fitted with bolted connections can be assembled. Multiple flat and loose structural parts can also be connected afterwards by means of (galvanized) bolts and nuts. However, if the object is so large or complicated that it needs to be welded after galvanization, a number of things must be taken into account.

recommendations

It is recommended that the zinc coating be removed over a sufficient width on either side of the weld to be applied. This is best done by blasting or grinding. In practice, however, welding is also done directly to the hot-dip galvanized steel without removal of the zinc layer on site. As a result, the zinc layer immediately adjacent to the weld will largely disappear during welding. In both situations, it is therefore necessary to touch up the zinc layer after welding.

POINTS OF ATTENTION WHEN WELDING TO GALVANIZED STEEL

Due to the high temperature during welding, the zinc layer on both sides of the weld melts and evaporates. This affects the welding process such that, with respect to the welds, adjustments are necessary. For example, gray zinc oxide fumes are generated during the welding process, preventing visibility of the work. Furthermore, spatter occurs and the welding process becomes “agitated.” Pores may also form in the welding. The zinc vapor released is not only sickening (temporarily causing nausea when inhaled), it also hinders a good view of the weld. In the workshop, the use of a welding exhaust is definitely necessary. Should one have to work on the construction site in a hall or in the open air, one should ensure that there are good ventilation possibilities and that one has the wind at one’s back so that the zinc vapor moves away from you. Understandably, the amount of welding vapor increases the thicker the zinc layer and the greater the welding speed. Finally, direct welding to hot-dip galvanized steel can create more spatter as well as gas inclusions in the weld.

UPDATE

After welding, the weld surface and adjacent areas where the zinc coating has evaporated must be provided with corrosion protection at least equal to that of hot-dip galvanized steel. For this, see Technical Data Sheet 2: Procedure for touch-up.
If the structure requires welding after galvanizing, the client will need to be consulted. It is likely that after welding and repairs, the object as a whole will no longer meet the requirements listed in EN-ISO 1461. In practice, restoring the zinc layer by using a zinc-rich paint is most common. Apply the paint with a long-haired brush to build up sufficient layer thickness. A spray of zinc spray will produce too little layer thickness. Touch-up can also be done by scooping (thermal zinc spraying) and other paint systems are also possible.

EN ISO 1461
Coatings applied by hot-dip galvanizing to iron and steel objects – Specifications and test methods.

EN ISO 14713 part 1
Zinc coatings – Guidelines and recommendations for the protection of iron and steel in structures against corrosion – Part 1: General design principles and corrosion resistance.

EN ISO 2063 part 2
Thermal spraying – Zinc, aluminum and their alloys – Part 2: Performance of corrosion protection systems

TECHNICAL DATA SHEET 2
Procedure for updating