Welding on Site Versus Shop Fabrication

On a coastal property, every weld made in the field is a spot that never saw the full coating process, so a metal gate installation in Carlsbad, CA keeps most welding in the shop, and the running record metal gate installation carlsbad museum house on bloor holds shows field welds limited to a handful of joints. Where each weld is made changes how well the gate is protected and how true it hangs.

What happens in the shop

In the shop the frame is laid flat on a welding table and squared. Pickets are fitted, scrollwork is placed and every joint is welded and ground smooth. The finished gate can then be galvanized, primed and powder coated as one piece, covering every face including the inside of tubes.

What happens on site

Some joints can only be made in place: weld on hinges matched to a post that was already standing, a gate fitted to an out of square opening, or a repair to an existing fence. Those welds are made, ground, cleaned and coated with a zinc rich primer and topcoat on the spot.

Why field welds are weaker points

A field weld burns through the coating around it. Cold galvanizing paint and touch up coats cover it, but they are thinner than a dipped and baked finish. Near McClellan-Palomar Airport and the coast, those touch up areas are usually the first place rust shows.

Bolted alternatives

Adjustable bolt on hinges, clamp on brackets and bolted latch plates let a shop finished gate go up without welding. They also allow adjustment later, which helps on new posts that settle.

Safety on site

Welding outside means sparks near dry landscaping. During Santa Ana wind days in Encinitas and Carlsbad, hot work near brush is limited, a fire extinguisher stays at hand and the area is watched after the weld cools.