How to Weld Galvanized Steel?


Galvanized steel is coated with a layer of zinc to protect it from corrosion. When welding galvanized steel, it's essential to take certain precautions to ensure a successful and safe weld. Here are some important steps and considerations for welding galvanized steel.


1. Safety Precautions

Welding galvanized steel produces fumes that can be harmful if inhaled. Ensure you have proper ventilation in the work area, wear appropriate personal protective equipment (PPE) such as a respirator, safety glasses, gloves, and protective clothing.

2. Remove the Galvanized Coating

Prior to welding, it's necessary to remove the galvanized coating from the areas to be welded. The zinc coating can release toxic fumes when heated, leading to weld defects and health hazards. Use a wire brush, grinder, or chemical solvent to remove the zinc layer. Make sure to remove the coating at least 1-2 inches beyond the weld area.

Welding Techniques

1. Choose the Right Welding Process

Different welding processes can be used for welding galvanized steel, such as shielded metal arc welding (SMAW), gas metal arc welding (GMAW/MIG), or flux-cored arc welding (FCAW). Select the process that best suits your application and skill level.

2. Set the Welding Parameters

Adjust the welding parameters based on the thickness of the base metal and the joint configuration. Consult the welding procedure specifications (WPS) provided by the welding electrode or filler wire manufacturer for recommended settings.

3. Use Low Welding Current

Galvanized steel has a lower melting point than the base metal, so it's important to use lower welding currents to prevent excessive heat buildup. This helps minimize the risk of burn-through and distortion.

4. Employ Short Arc Technique

When welding galvanized steel, use a short arc technique to control the heat input. This involves keeping the arc length short to minimize heat affected zone (HAZ) and reduce the chances of zinc evaporation.

Post-Weld Treatment

1. Clean the Welded Area

After welding, clean the welded area to remove any slag, spatter, or residue. Use a wire brush or grinding wheel to smooth the surface and ensure proper adhesion of any subsequent coatings or paints.

2. Apply Anti-Spatter Spray

To minimize the risk of spatter adhering to the welded surface, apply an anti-spatter spray or solution as per the manufacturer's instructions. This helps in easy removal of spatter and provides a cleaner finish.

3. Post-Weld Coating

To restore corrosion resistance after welding, consider applying a post-weld coating or paint to the welded surface. Consult with coating manufacturers for suitable products that adhere well to galvanized steel.


Welding galvanized steel requires proper preparation, welding techniques, and post-weld treatments to ensure successful and safe welds. By following the necessary precautions and employing suitable welding processes, you can achieve strong and durable welds on galvanized steel.