Table of Contents

Hot-Dip Galvanizing for Corrosion Protection.......3

Welding Before Galvanizing.........................................3
Weld Metal Chemistry..........................................3
Weld Cleanliness....................................................4
Seal Welding Before HDG..................................4
Before HDG Summary.........................................5
Welding After Galvanizing...........................................5
Preparation of Weld Area....................................5
Weld Metal Chemistry..........................................5
Welding Methods...................................................5
Gas Metal Arc (GMA)........................................5
Shielded Metal Arc Welding (SMAW)............6
Oxyacetylene....................................................6
Touch-Up of Weld Area.........................................6
Quality of Welded Joints......................................7
Fracture Toughness................................................7
Fatique Strength.....................................................7
Porosity.....................................................................7
Health & Safety........................................................7
After HDG Summary..............................................7

2009 American Galvanizers Association. The material provided herein has been developed to provide accurate and authoritative
information about after-fabrication hot-dip galvanized steel. This material provides general information only and is not intended as a
substitute for competent professional examination and verification as to suitability and applicability. The information provided herein
is not intended as a representation or warranty on the part of the AGA. Anyone making use of this information assumes all liability
arising from such use.
Hot-Dip Galvanizing (HDG) for
Corrosion Protec tion Zinc, as it is used in galvanizing, is a healthy metal, completely
recyclable. The energy used to produce zinc from ore is
As it becomes more common to specify hot-dip galvanizing inversely related to the amount of zinc recycled. Galvanizing
(the metallurgical combination of zinc and steel) as the delivers incredible value in terms of protecting our
corrosion protection system for structural steel fabrications, it infrastructure. Less steel is consumed and fewer raw
is essential to understand considerations for the galvanizing of materials are needed because galvanizing makes steel
welded black steel or for welding on galvanized steel and the structures, bridges, roads, and buildings last longer. Over
need to integrate them into the overall structural fabrication time, galvanizing helps maintain steel fabrications
design. Welding before and after galvanizing is common; the structural integrity galvanized structures are safer.
requirements are relatively simple for a designer to
implement, resulting in superior corrosion protection. Additionally, because galvanized steel requires no
maintenance for decades, its use in public construction is an
The galvanizing process has existed for more than 250 years efficient use of our taxes. Selecting galvanized steel for
and has been a mainstay of North American industry since private projects makes a significant contribution to a
the 1890s. Galvanizing is used throughout various markets to companys profitability.
provide steel with unmatched protection from the ravages of
corrosion. A wide range of steel products from reinforcing
steel to playground equipment to professional sports stadiums Welding Before Galvanizing
to the artistic expression of todays sculptors benefit from
galvanizings superior corrosion protection properties. To achieve a high-quality hot-dip galvanized coating on
welded areas of fabrications, three important issues must
Galvanizings primary component is zinc. This vital metal is be considered before galvanizing: chemical makeup of the
silvery-gray in color and naturally found in the Earths crust, weld metal, cleanliness of the weld area, and continuity of
ranking 27th in order of abundance. It is essential for the a seal weld.
growth and development of all life. Between 1.4 and 2.3 grams
of zinc are found in the average adult, and the World Health
Organization has recommended a daily intake of 15
Weld Metal Chemistry
milligrams. Numerous consumer products, including cold The galvanized coating coats almost any type of iron or steel,
remedies, sunscreens, diaper creams, and nutritional and the coating thickness primarily depends on the silicon
supplements, contain beneficial amounts of zinc, primarily in content of the iron or steel part. The major difference
the form of zinc oxide. between the weld metal and the structural steel is the amount
of silicon in the weld rod. Excessive silicon in the weld
Even though galvanized steel is gray, it can also be green. The filler material can accelerate the growth of the hot-dip
zinc and galvanizing industries work to promote sustainable galvanized coating. Because some weld rod metal contains
development by enhancing zincs contribution to society and nearly 1% silicon, the difference between the coating
ensuring its production and use are in harmony with the thickness on the weld metal and the surrounding structural
natural environment and the needs of society, now and in the steel can be significant. Excessive silicon in the weld material
future. to be galvanized causes an

American Galvanizers Association 3

accelerated formation of the zinc-iron intermetallic layers that Welding Process Welding Rod Material Silicon Content
make up the hot-dip galvanized coating, greatly increasing SMAW Jetweld 2 0.30%
coating weight (Figure 1). Fleetwood 35 LS 0.11%
Fleetwood 7 0.33%
SAW L61 - 860 3.40%
9 FCAW NR 203 NiD 0.04%
8 NR 311 0.07%
Coating Weight (oz/ sq ft)

NR 431 0.21%
7 High Silicon Steel

6
Table 1
5 5.0 oz/ft
2
Table 1 indicates the material and chemistry for several
4 welding rods that have been tested by the AGA and produce
3 coatings comparable to low silicon steel.
Low Silicon Steel
2

1
2.2 oz/ft 2
Weld Cleanliness
Typical Galv Time
0 2 4 6 8 10 12 When welded structures are hot-dip galvanized, the weld
Galvanizing Time (minutes) areas cleanliness significantly affects the quality and
appearance of the galvanized coating around the weld
Figure 1 (Figure 3). If a coated electrode is used during welding, all
When the fabricated structure is immersed in the zinc bath welding flux and slag must be removed prior to galvanizing
long enough to achieve a coating that meets the minimum or the zinc coating will not adhere to the weld area (Figure
thickness of the galvanizing standards (such as ASTM A 123/ 4). Chemical cleaning solutions used in the galvanizing process
A 123M, Standard Specification for Zinc (Hot-Dip cannot remove weld flux and slag. Slag and flux must be
Galvanized) Coatings on Iron and Steel Products), the coating removed by wire brush, flame-cleaning, chipping with a pick,
on the high- silicon weld metal can be more than two-times grinding or abrasive blast-cleaning prior to the galvanizing
thicker than the surrounding coating. This thick coating on process. Slag not removed from the steel surface will cause a
the weld detracts from the appearance of the fabricated bare spot in the coating.
structure and increases the possibility of the zinc coating
becoming damaged in the weld area with further handling of
the assembly or part.

For typical welding processes, such as shielded metal arc

welding (SMAW), submerged arc welding (SAW) and flux-cored
arc welding (FCAW), there are weld rod materials that will not
cause excessively thick coatings as shown below (Figure 2).

P
Figure 3
Seal Welding Before HDG
Figure 4
W
On assemblies with contacting surfaces having a gap of less
than 3/32 (2.5 mm), a full seal-weld can be used on all edges,
depending on the size of the overlapped area (Figure 5). Zincs

Figure 2: Typical weld results

4 American Galvanizers Association Figure 5

viscosity prevents it from entering any space smaller than coating should be removed at least one to four inches (2.5-10
3/32 (2.5 mm), resulting in ungalvanized surfaces. cm) from either side of the intended weld zone and on both
Ungalvanized surfaces in tight spaces will corrode and bleed sides of the workpiece. Grinding back the zinc coating is the
iron oxide onto the surrounding galvanized surfaces, making preferred and most common method; burning the zinc away
for an unsightly appearance. Cleaning solutions have lower or pushing back the molten zinc from the weld area can
viscosities, allowing them to enter these small gaps. Cleaning also be used.
solution salts can be retained in these tight areas and humidity
encountered weeks or months later may wet these salts and
cause iron-oxide weeping. Weld Metal Chemistry
Because the galvanizing has already taken place, selection of
A second design consideration is to use equal or nearly weld material is less critical. It is important to avoid zinc in
equal thickness of assembly pieces, with symmetrical welds the weld and proper preparation of the area to be welded as
(Figure 6). During galvanizing, the assembly is heated to the previously described assures a quality weld.
molten zinc bath temperature more than 815 F (435 C) and
then cooled to ambient temperature. When welded pieces Welding Methods
of dissimilar thickness are galvanized, one of the pieces will The three methods of manual/semi-automatic welding
often have a high stress induced in the fabrication process detailed here are more flexible than resistance or laser welding,
and/or by the galvanizing temperature changes. If the stress which are not used on batch galvanized assemblies. All three
is high enough, distortion of the assembly, or in extreme manual/semi-automatic methods benefit from the removal of
cases, a fracture of the weld or of the stressed piece in the zinc from the areas to be welded, but zinc removal is not an
assembly can occur. Galvanizing welded fabrications is a absolute requirement.
common method of protecting a structure from corrosion.
Gas Metal A rc Welding
(GMAW )
Particularly suited to welding of thinner materials, gas
metal arc welding (GMAW), also known as CO2, is a
convenient and versatile semi-automatic welding
process (Figure 7). The presence of the zinc coating has
no effect on weld mechanical properties, although it may
produce some appearance changes due to weld spatter.
Arc stability is excellent and generally unaffected by the
galvanized coating.

Figure 6

Welding Before HDG Summary

A high-quality hot-dip galvanized coating, even over welded
areas, is achieved by properly selecting a weld metal, thoroughly
cleaning the slag from the weld area, and using good design
practices.

Welding After
Galvanizing
Many commonly practiced welding and cutting techniques Area
can be used on galvanized steel (see American Welding
Societys (AWS) specification D-19.0, Welding Zinc Coated Steel). AWS D-19.0, Welding Zinc Coated Steel, calls for welds
Welding on galvanized steel can be necessary if the final to be made on steel free of zinc in the area to be
structure is too large to be dipped in a galvanizing bath or for welded. Thus, for galvanized structural components of a
structures that must be welded in the field. fabrication, the zinc
American Galvanizers Association 5
Preparation of Weld
 Figure 7

There may be a reduction in welding speed because the

galvanized coating must be burned off ahead of the weld. The
use of a 100% CO2 weld shield gas is acceptable for
galvanized steel and there are no advantages to using more
expensive shielding gas combinations. Penetration of the weld in
zinc-coated steels is less than for uncoated steels. Therefore,
slightly wider gaps must be provided for butt-welds.
The major difference between welding zinc-coated steel Weaving and multiple weld beads should be avoided,
and welding uncoated steel using the GMAW process is as should excessive heat injection into the joint.
the need for higher heat input to remove the zinc from the Excess heat may damage the adjacent zinc coating.
weld pool and lower welding speeds to burn off as much of
the zinc coating ahead of the weld bead. A short arc length is recommended for all positions
to give better control of the weld pool and to prevent
Typical welding conditions for CO2 welding of butt-joints either intermittent excessive penetration or
on hot-dip galvanized steel are available in AWS D19.0, undercutting.
Tables Slightly wider gaps are required in butt-joints in
5.5 through 5.12. order to have complete penetration.

Shielded Metal Arc Welding (SMAW ) Grinding off edges prior to welding give the best
quality weld joint. It also reduces fuming from the
This most common of the manual processes uses flux- galvanized coating. Welding procedures will then be
covered electrodes. The conditions necessary for Sheilded the same as for uncoated steel.
Metal Arc Welding (SMAW) or Manual Metal Arc
Welding (MMAW) are similar to those used on Electrodes similar to those used for arc welding uncoated
uncoated steel. However, the speed of the welding may steel may be used. The major difference when MMAW
be slower because the angle of the electrode is reduced galvanized steel compared to uncoated steel is the need
to about 30 and a whipping motion of the electrode back for higher heat input to remove the zinc from the weld pool
and forth is required to move the molten zinc pool away and lower welding speed to burn off as much of the zinc
from the weld (Figure 8). from the leading edge of the pool. This may result in
greater fluidity of the slag and increased splatter.

Oxyacetylen
e
Preparation for oxyacetylene fusion welding is similar to
that for welding uncoated steel. Because low travel speed
is necessary to bring the joint edges to the fusion
temperature, the extra heat causes the zinc coating to be
affected over a much greater area than other welding
processes. Best results are obtained when the filler rod is
moved back and forth, producing a ripple weld.

Figure 8
Touch-up of Weld
The major difference between welding zinc-coated steel
and welding uncoated steel using the SMAW process
Area
is the root opening must be increased to give full weld Any welding process on galvanized surfaces damages the
penetration. The amount of spatter formed when SMAW is zinc coating on and around the weld area. Restoration of the area
used is slightly higher than for welding on uncoated steel. should be performed in accordance with ASTM A 780, Practice
for Repair of Damaged and Uncoated Areas of Hot-Dip
Typical SMAW conditions for the root pass in butt-welds on Galvanized Coatings, which specifies the use of paints containing
batch galvanized steel are available in AWS D19.0, zinc dust, zinc-based solders, or sprayed zinc. All touchup
Tables and repair methods are capable of building a protective layer
6.2 through 6.5. to the thickness required to provide corrosion protection.

MMAW is recommended for galvanized steels of 1/2 The restored area of the zinc coating will have no affect on the
(1.27 cm) thickness or greater. In general, welders can overall lifetime of the part. Repair materials and their coating
use the same procedures for galvanized steel as for thickness have been chosen to give comparable lifetimes to
uncoated steel, although the following should be noted: the coating minimums required by ASTM A 123/A 123M,
Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and
The electrode should be applied slower than normal, Steel Products. There may be some visual differences between
with a whipping action that moves the electrode the original hot- dip galvanized coating and the restored
forward along the seam in the direction of the weld area, but over time, the natural weathering of the galvanized
and then back into the molten zinc pool. coating can blend the two appearances or can accentuate
the different apperances depending on the choice of repair
materials.
6 American Galvanizers Association
Quality of Welded Joints necessary to consider both the function of the joint and the
weld size.
AWS D19.0 recommends removing all zinc from the weld
area prior to welding because burning through the zinc When a fillet weld on galvanized steel is large enough
slows the welding process, generates zinc fumes (see Health & relative to plate thickness to fail by fatigue from the toe of
Safety next column), and creates an unsightly burn area around the weld in the same manner as in uncoated steel, the
the weld. presence of porosity in the weld does not reduce the fatigue
strength of the joint. Where the dimensions of the weld are just
However, as studies performed by the International Lead Zinc
large enough to cause fatigue failure from the toe in a sound
Research Organization (ILZRO) have shown, the tensile, bend
weld, a weld containing porosity at the root may fail
and impact properties of welds on galvanized steel are
preferentially through the throat of the weld. Intergranular
equivalent to the properties of welds on uncoated steel.
cracking of fillet welds containing porosity, sometimes
referred to as zinc penetrator cracking, does not significantly
Fracture Toughness affect the strength of non-critical joints. For more critical
In the same study as mentioned above, ILZRO established the stress applications, it is advisable to carry out procedural tests
fracture toughness properties of welds are unaffected by the on materials and samples.
presence of galvanized coatings.
Health & Safety
Fatigue Strength All welding processes produce fumes and gases.
The fatigue strength of arc welds on galvanized steel is Manufacturers and welders must identify the hazards associated
equivalent to welds on uncoated steel made by CO2 welding with welding coated and uncoated steel and workers must
as shown in Figure 9. be trained to maintain work practices consistent with
Occupational Safety and Health Administration (OSHA)
regulations. In general, welding on steel with the zinc coating
ground away from the weld area will produce lead and zinc
oxide emissions below OSHA permissible exposure limits
(PELs). When welding directly on galvanized steel is
unavoidable, PELs may not be surpassed in open area, but
may be exceeded in confined areas and every precaution,
including high-velocity circulating fans with filters, air
respirators and fume-extraction systems suggested by AWS,
should be employed.
Fumes from welding galvanized steel can contain zinc,
iron, and lead. Fume composition typically depends on the
composition of materials used, as well as the heat applied by
the particular welding process. In any event, good ventilation
Figure 9 minimizes the amount of exposure to fumes. Prior to welding
Porosity on any metal, consult ANSI/ASC Z-49.1, Safety In Welding,
Cutting and Allied Processes, which contains information on the
The extent of weld porosity is a function of heat input and the protection of personnel and the general area, ventilation and
solidification rate of the weld metal. Not always possible to fire prevention.
eliminate, porosity affects the fatigue strength and cracking
tendencies of welds.
Welding After HDG Summary
When welds are subject to fatigue loading, welds on
galvanized steel should be made oversized to reduce the With proper preparation of the weld area, selection of a
influence of any weld metal porosity or zinc inclusions. When suitable welding material and process, and careful touch-up
evaluating the effect of porosity on the fatigue strength of a of the weld area, welding on galvanized steel provides an
fillet weld, it is excellent product for use in myriad applications, from
bridges, towers, and grating to handrail, trusses, and guardrail.

American Galvanizers Association 7

American Galvanizers Association 7
American Galvanizers Association
6881 South Holly Circle, Suite 108
Centennial, CO 80112
720.554.0900
www.galvanizeit.or
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