What step should be taken regarding galvanised coatings when welding, when possible?

• A. Remove galvanised coatings when possible
• B. Weld directly over coatings
• C. Increase amperage to burn off coating
• D. Use water to cool coating

Answer: (A)

Removing galvanized coatings before welding is essential because heating zinc releases fumes that irritate and can harm the welder’s lungs; exposure can cause metal fume fever and respiratory discomfort. The zinc fumes can also contaminate the weld pool, leading to porosity and weakening of the weld. By taking off the coating, you get a cleaner, stronger weld and reduce health risks. If removal isn’t possible, ensure proper ventilation and fume extraction and use appropriate PPE, rather than trying to burn off the coating with more heat or cooling it with water, both of which create additional hazards and weld defects.