Safety 101: Welding Galvanized Steel Sans the Hazards

Hot dip galvanizing, more commonly known as galvanizing, is the process of applying zinc coating to fabricated iron or steel by immersing the said material in a bath consisting of usually molten zinc, mainly for erosion and corrosion prevention. Galvanizing has been used in variety of applications, from protecting iron and steel from rusting in cable ropes in suspension bridges, to the automobile industry's dependence on galvanizing for the production of many vehicle components.

The same welding process can be used with little or no modification when welding Jacksonville FL steel, uncoated or galvanized, unless the zinc coating is unusually thick. However, the difference between welding uncoated and galvanized steel lies in the vaporization temperature of zinc. Zinc melts at 900 degrees Fahrenheit and vaporizes at 1650 degrees Fahrenheit. Because steel melts at 2,750 degrees and the welding temperature is 15,000 to 20,000 degrees, the zinc coating is immediately vaporized.

Zinc vaporization has two immediate consequences. It increases the volume of welding smoke and fumes, and the zinc is burned by the heat, removing it entirely. The protective coating must then be reapplied. Furthermore, when zinc vapor mixes with the oxygen in the air, the compound results in zinc oxide. While there are no long term effects of inhaling zinc oxide, research suggests that breathing in those fumes will cause flu-like symptoms.

Additionally, current studies concentrate on the mechanisms by which zinc oxide, which results in welding Jacksonville FL has to offer, contribute to the "metal fume fever." While not entirely detrimental to one's health, the consequences of metal fume fever lie in its aftereffects. Typical metal fume fever starts about four hours after initial exposure. Symptoms include fever, chills, thirst, headache, and nausea. All of these symptoms, which result in lost work time, reduce productivity.

Metal fume fever can be avoided simply by not inhaling zinc oxide and following safety precautions. Defense against zinc oxide fume installation lies in welder training. Welders should be taught to keep their heads out of the fume plumes and to position themselves in areas with continuous air flow so that dust and fumes do not collect in their welding shields. Wearing gas masks also effectively filter out what the welders breathe in, protecting them from unwanted fumes.

Another approach in preventing zinc oxide inhalation is to capture the fumes so that it does not rise to the welders' faces. Common fume capturing devices when welding Jacksonville FL steel are ducts attached to exhaust or filter systems. However, one difficulty in many fume capturing mechanisms is their limited range which is usually less than a foot. This means that the welder also has to move the duct if he moves outside its range.