Regarding galvanized pipe arc welding

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Russ2251

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What are the dangers of arc welding galvanized steel (electrical conduit) from the "I don't want to destroy my lungs" standpoint?

How can potential problems be avoided?

Does galvanized steel need any prepping?

Anything else I should be aware of?

I've been avoiding welding anything in the last couple of decades...but now I have no choice.
Thanx.
 

freakboy

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I belive it would be more toxic then the normal welding fumes. just grind off the galvanizing in the area and like all welding weld in a open area.
 

jr dragster T

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The effects from any heavy metal poisoning range from mild flu like symptoms to VERY VERY severe symptoms. Best bet would be to grind 2" away from seem and have good ventilation. The hazard is still there even when grinding off the zinc/galv. It all comes down to being very careful.
 

freakboy

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You also might want to try wearing a resperator or a small dust mask anything to prevent directly breathing it in.
 

frederic

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Another option is to wear a canister-based breathing mask while welding, specifically designed to remove heavy metals and similar pollutants. If you have such a mask from painting vehicles, that's the one that will do the trick.

Because they're fairly large and cover a fair portion of your face, you'll never get your welding mask over the canisters so you can adapt and use them a different way as I have. The canisters clip on my belt and I clip them behind my back, then run a flexible plastic tube from my mouth to a fitting I machined which the canisters screw into. I call this a "back breather" because I'm breathing filtered air from behind my back through the canisters. The mouth end has a piece of a "snorkling snorkle" I hacksaws the mouthpiece off and glued the tubing in.

Of course if you don't have a canister breather apparatus to begin with, it's an expensive option to make one as compared to purchasing ordinary mild steel tubing that's not zinc coated.

Electrical conduit is not really a structural tube, it's designed to contain fires and burned wires and nothing more. It's bent easily with simple lever-based anvils and with the very thin wall they have little strength after getting a few dings, dings that are likely on a moving kart.

You'd probably be better off with mild steel tubing with a 1/16-1/8" wall to be honest.

BTW, any kind of welding produces noxious fumes that can kill you. Vaporized zinc just makes those fumes even more noxious.
 

Russ2251

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Am using this stuff for a lighter exhaust system. No biggie if it doesn't work. I have several dozen feet of this stuff just laying around and don't want to trash it for cash just yet.
You know how it goes. The day after I trash it...I'll come up with a use for it.
 

Rickracer

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I don't know if you've tried it yet, but if you don't grind off the galvanizing, your welds will not stick and will look like a$$. I use galvanized pipe sometimes when the project is something where strength or looks aren't critical and I happen to have the material handy, or sometimes I repair or build fence gates made from galvanized materials. You can tell when you have ground through the galvanizing because it's kinda dull looking, when you get to clean steel, it will be brighter looking. I usually use 50 or 36 grit roloc sanding discs to clean off the galvanizing. If it's thin stuff like conduit, 50 grit would be better, the coating isn't as thick as it is on galvanized pipe. Hope this helps....:cool:
 

t0x1k

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I don't see how grinding will make a difference, it's plated galvanized, it's plated inside and out.
Just used a respirator certified for lead dust and you'll be safe. I've never had any issues with it and I don't wear a mask, I just naturally hold my breath while i weld, keeps the hands steady.
 
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