Need safety tips for cutting galvanized steel conduit with my angle grinder

Hey guys, I'm working on a small backyard shed project and need to run some electrical. I picked up some 1/2" galvanized steel conduit from Tool Discount Club last week. I've got my angle grinder with a metal cutting wheel, but I've never cut this stuff before. Heard it can throw nasty sparks or even catch fire? What's the safest way to do this without ending up in the ER? Should I be wearing something more than my usual safety glasses and gloves?

Dan, LISTEN UP - this is serious. Galvanized steel produces zinc oxide fumes when cut with heat (like from your grinder). Those fumes can cause metal fume fever - basically like a bad flu that hits you 4-12 hours later. You NEED: 1) A respirator with P100 filters (not just a dust mask), 2) FULL face shield (sparks will fly everywhere), 3) Fire extinguisher nearby (yes, the coating can ignite), 4) Cut in well-ventilated area, preferably outside. And for god's sake, secure the conduit in a vise - don't hold it with your hand. Saw a guy at a jobsite last year who didn't respect this stuff and was out sick for three days.

SafetySteve's not kidding about the fumes - we tile guys deal with similar issues cutting galvanized corner beads. I'd add: use a NEW cutting wheel, not some worn-out one that'll bind and kick back. Mark your cut line with a marker, go slow and steady. And maybe consider a different tool? A reciprocating saw with metal blade creates less heat/sparks, or even a hacksaw if it's just a few cuts. But if you're set on the grinder, everything Steve said plus leather apron - those sparks burn right through cotton.

All good advice above. From a landscape perspective - make sure there's no dry vegetation or flammable materials within 15 feet. I once saw a spark ignite some mulch piles. Also, galvanized coating creates sharp edges after cutting - file those down immediately or you'll get a nasty gash reaching into the conduit later. Tool Discount Club sells a decent deburring tool for like $8. Stay safe, post pics of the shed when done!