Here is a little primer for welding galvanized metals. And I have to say I welded a lot of galvanized metals and never experienced any effects myself. But to each their own. JMHO
Welding Galvanized Steel
The difference between welding galvanized steel and welding uncoated steel is a result of the low vaporization temperature of the zinc coating. Zinc melts at about 900˚F and vaporizes at about 1650˚F. Since steel melts at approximately 2,750˚F and the welding arc temperature is 15,000 to 20,000˚F, the zinc that is near the weld does not stand a chance -- it's vaporized! By the time the weld pool freezes, the zinc is gone. This has two immediate consequences: ? The vaporized zinc increases the volume of welding smoke and fumes. ? The zinc at and near any welds is actually burned off by the heat of the arc, removing the protective zinc coating.
Zinc Fumes -- A Safety Hazard? When zinc vapor mixes with the oxygen in the air, it reacts instantly to become zinc oxide. This is the same white powder that you see on some noses at the beach and the slopes. Zinc oxide is non-toxic and non carcinogenic. Extensive research into the effects of zinc oxide fumes has been done, and although breathing those fumes will cause welders to think that they have the flu in a bad way, there are no long-term health effects. Zinc oxide that is inhaled is simply absorbed and eliminated by the body without complications or chronic effects. Another area of research is use of zinc compounds as the active ingredients in throat lozengers that are recognized as significantly effective in reducing the duration and intensity of the common cold.
