Skill: Arc Welding – Basics for Gate and Bracket Fabrication
Skill level: 4
Fabrication
Learning Objective
Understand how to safely and effectively perform basic arc welding (stick welding) for joining steel components such as hinges, brackets, gate frames, or post fixings.
1. Overview
Arc welding (stick welding) uses an electric arc to melt a consumable electrode and fuse steel parts together. It’s widely used in gate and bracket fabrication because it:
Produces strong joints on heavy steel
Works well outdoors and in breezy conditions
Requires simple, portable equipment
Is easy to learn, practice expedites progress
❌ Poor welding technique = weak joints, distortion, and costly rework.
2. Tools & Materials Required
Arc welder (inverter or transformer type)
Welding rods (e.g. 6013 general purpose)
Earth clamp and clean workpiece
Wire brush or flap disc
Welding hammer / chipping hammer
Steel clamps or magnets for holding parts
PPE:
Auto-darkening welding mask
Leather gloves
Fire-resistant long sleeves
Work boots
Welding apron (optional)Fire extinguisher
Fume extraction (if indoors)
3. Before You Start (Design and Planning)
Clean steel surfaces of rust, paint, grease or galvanising.
Check fit-up: tack components squarely before welding.
Select rod size for material thickness (2.5mm rod ≈ 90–100A, 3.2mm ≈ 120–130A).
Plan weld sequence to minimise distortion.
Ensure work area is free of flammables and well-ventilated.
Place welding screen if others are nearby.
4. Procedure
A. Set Up
Attach earth clamp directly to workpiece.
Insert electrode into holder, set correct amperage.
B. Striking the Arc
Strike like a match or tap method.
Maintain 2–3mm arc gap.
Hold electrode at 15° angle, leaning away from travel.
C. Welding Pass
Move steadily at consistent speed.
Listen for “crackling bacon” sound (correct arc).
Use straight stringer bead for thinner work.
Use weaving motion for thicker joints.
D. After Weld
Allow weld to cool slightly.
Chip slag with hammer, brush clean.
Inspect weld: even bead, no holes or undercut.
5. Best Practices
Always weld on clean metal only.
Use short tacks first to hold alignment.
Keep rods dry and store properly.
Maintain steady travel speed — too fast = weak, too slow = burn-through.
Chip and brush between passes.
Practice on scrap before critical welds.
6. Common Mistakes to Avoid
🚫 Welding on rusty/painted/oily steel → weak welds
🚫 Wrong amperage setting → sticking rods or excessive spatter
🚫 Travelling too fast → thin bead, poor penetration
🚫 Travelling too slow → overheating and distortion
🚫 Not removing slag → hides poor weld quality
🚫 Ignoring PPE → risk of burns or arc eye
7. Safety Information
Relevant SSOW References:
SSOW-03: Drilling, Cutting, and Welding Safety
SSOW-07: Safe Use of Power Tools & Welding Equipment
SSOW-09: Hot Work Permits & Fire Watch
SSOW-11: PPE – Gloves, Safety Glasses, Welding Mask, Protective Clothing
SSOW-13: Fume Extraction and Ventilation Safety
