How to Weld a Steel Chain Link onto a Plate Hook

Welding a steel chain link onto a plate hook is a practical repair or fabrication task, but it must be done correctly — especially if the assembly will carry any load. A poor weld on a lifting or rigging application can fail catastrophically, so understanding the process and your own skill level is essential before you start.

Understand the Application First

Before picking up a welder, ask yourself: what will this hook-and-chain assembly be used for? If it's a decorative item, a gate latch, or a light-duty anchor point, a competent DIYer with basic welding experience can tackle this job. However, if the assembly will be used for lifting, rigging, or load-bearing applications, this is a different matter entirely.

In New Zealand, lifting equipment and rigging gear used in workplaces is governed by WorkSafe NZ regulations. Welded chain links used for lifting must meet specific standards and should only be fabricated or repaired by a qualified tradesperson. Never weld a standard chain link for lifting purposes unless you are a certified welder working to the relevant standard — welding can alter the metallurgy of the chain and reduce its rated capacity.

Materials and Equipment You'll Need

• MIG welder (a 150–200 amp machine is suitable for most mild steel chain and plate hook work) or a stick (MMA) welder
• Welding helmet (auto-darkening recommended)
• Welding gloves and leather apron
• Angle grinder with flap disc and cutting disc
• Wire brush and degreaser
• Clamps or a welding vice
• Steel chain link (grade and diameter to suit your application)
• Plate hook (mild steel is easiest to weld; check it isn't hardened or galvanised)

You can source welding consumables and safety gear from Bunnings or Mitre 10, or from a specialist welding supply shop.

Step 1 — Identify Your Steel

Know what you're welding. Mild steel (low carbon) chain and hooks weld readily with standard MIG or stick processes. However:

• Hardened or high-tensile chain (often used in lifting) can crack when welded due to its carbon content. Do not weld this without specialist knowledge.
• Galvanised steel releases toxic zinc fumes when welded. If your hook or chain is galvanised, you must grind off the coating in the weld area and work in a very well-ventilated space. Refer to WorkSafe NZ guidance on welding fume hazards.

If you're unsure of the steel grade, consult a qualified welder or the material supplier.

Step 2 — Prepare the Surfaces

Good preparation is the foundation of a strong weld.

1. Clean the weld area on both the chain link and the plate hook. Use an angle grinder with a flap disc to remove any rust, paint, or mill scale from the contact zones.
2. Degrease both parts with a suitable solvent or degreaser — oil and grease cause porosity and weak welds.
3. Position the chain link on the plate hook where you want it welded. Consider which part of the link will bear the load and orient it accordingly.

Step 3 — Set Up and Tack Weld

1. Clamp or fixture the assembly securely so it won't move during welding. A welding vice or magnetic clamp works well.
2. Set your welder to suit the material thickness. For mild steel chain link of 8–10 mm diameter, a MIG welder set to around 130–160 amps with 0.8 mm or 0.9 mm wire is a reasonable starting point — always check your welder's chart and test on scrap first.
3. Apply tack welds at two or three points to hold the link in position before running your full welds.

Step 4 — Run the Welds

• Weld both sides of the chain link where it contacts the plate hook. A single-sided weld is rarely sufficient for any practical application.
• Use a smooth, consistent travel speed and maintain a short arc length to avoid porosity.
• Allow each weld pass to cool slightly before adding another pass if you need to build up the weld.
• Do not quench the weld in water — allow it to cool naturally to avoid hardening or cracking.

Step 5 — Inspect and Finish

1. Wire brush the weld to remove slag (if stick welding) and inspect visually for cracks, porosity, or undercut.
2. Grind any sharp edges or spatter that could cause injury or stress concentration.
3. If the assembly will be used outdoors, prime and paint with a suitable metal primer and topcoat to prevent rust. Resene and Dulux both offer metal primers suited to NZ conditions.

Safety Notes

• Always weld in a well-ventilated area or outdoors.
• Wear your full PPE: auto-darkening helmet, gloves, leather apron, and closed-toe boots.
• Keep a fire extinguisher nearby and clear the area of flammable materials.
• Never look at the arc without proper eye protection — even a brief flash can cause arc eye.
• Refer to WorkSafe NZ for comprehensive welding safety guidance.

When to Call a Professional

Call a qualified welder if:

• The chain-and-hook assembly will be used for lifting, rigging, or any safety-critical load-bearing purpose.
• You are working with high-tensile, hardened, or stainless steel and are unsure of the correct process.
• You don't have welding experience or the right equipment.
• The finished assembly needs to meet a specific standard or certification (e.g., for a workplace or commercial setting).

A qualified tradesperson will ensure the weld meets the job requirements and can certify the work where needed. You can find experienced local welders on tradedirectory.co.nz.

Sources & Further Reading

• WorkSafe NZ — Welding and cutting hazards
• BRANZ — Steel and metalwork guidance
• Bunnings — Welding equipment and PPE
• Mitre 10 — Welding and metalwork supplies
• Resene — Metal primers and protective coatings
• Standards NZ — Welding and fabrication standards