Before you start welding, you should make sure you have the correct gear, according to Michael Farrell. Steel toecap boots are essential. Overalls are important for personal protection also – 100% cotton or fire-retardant welder’s overalls are far preferable. Polyester or polyester cotton mix will not do, as they melt too easily under heat or flame.

Michael warns that anyone welding should have a good welding helmet (€20 to €40) and proper gloves (€9 to €12). He recommends helmets with a flip-up screen and visor so your eyes are always protected from flying slag.

Having your own work station will allow you to have your welding and safety equipment in one place. Michael says farmers should invest in a type C fire extinguisher suitable for welding machines.

In terms of welders, Michael says AC oil-cooled welding plants were the most popular. However, he said DC air-cooled welders have become very popular now because they are quite light, easy to move around, competitively priced and like the AC they are oil-cooled in most cases so do not give a lot of trouble. A generator welder can be in some cases a small investment and very handy to have around a farm. A welding generator can have extra benefits such as using a grinder or transportable lights in an area. However, sparks and petrol fuel can be quite dangerous and this should be considered before starting work.

Arc welding is a fusion process for joining metals. By applying intense heat, metal at the joint between two parts is melted and caused to intermix directly or, more commonly, with an intermediate molten filler metal. The earth has to go on to the steel that you are welding to create a circuit. A rutile flux rod (electrode) is the most common type used by farmers. The size of your steel will usually determine the amps and welding electrode required. A 2.5mm general-purpose mild steel welding rod set at 75 to 80 amps for normal box iron is usually sufficient.

Michael says to position the earth clamp as near as possible to what you are welding and make sure it is making good contact. Starting a welding rod off, to get it to arc (spark) can be tricky for a beginner. Once the arc is struck, it is a matter of maintaining the gap between the welding rod and work piece. Too close and the rod will stick and twist. Too far and weld spatter goes everywhere. Just right and you will hear a noise or crackle. The trick is to maintain that same distance and crackle while the rod burns away as you simultaneously drag the rod along to create the perfect weld. It takes a lot of practice and patience to get right.

A gauge of a good weld is where the weld slag either peels away altogether or lifts and crack. You need very little chipping with the hammer to clean the weld slag off. Again, spend some time practising on the flat to develop the right technique and knowledge of welding. Michael says vertical welding takes more practice, is more challenging and requires a lot more experience. One tip Michael gives someone planning on taking on a welding job is to have it finished in your head. “Don’t take on something you cannot do, there are professionals in every parish there for the more intricate jobs,” explained Michael.

Health and safety

  • Molten weld splatters – have both water and a fire extinguisher nearby. Keep work pieces secure.
  • Human skin is vulnerable to burns. UV light will also burn exposed skin, so cover up, especially if you are fair-skinned.
  • Make sure that electrical installations are protected and install the correct sockets.
  • Stop immediately if you feel overwhelmed by fumes.
  • Welding produces both ultraviolet and infrared light radiation. Use a welding mask with the correct light filter for eye protection. Never look at the welding process with the naked eye.
  • Use welding gloves and wear only 100% cotton or fire retardant welders’ overalls, as polyester or polyester cotton mix overalls will melt under heat or flame.

    • Course

    Lots of farmers are interested in taking part in the beginners’ course in winter, according to Michael. “Usually, farmers want to learn the basics of welding so that they can confidently do their own light repairs on link boxes and silage grabs, for example,” he said. “A part-time beginners course once a week for 10 weeks at night time that caters for farmers or anyone else interested in just basic repairs costs €400 to €450 in total.”