Which Welding Rod for Galvanized Steel
Top pick: E6011, starting at 40-85A on AC/DCEP. 3 rods compared with settings for this application.
Galvanized steel is coated with zinc to prevent corrosion. Welding on galvanized metal vaporizes the zinc, creating toxic zinc oxide fumes that cause metal fume fever (flu-like symptoms lasting 24-48 hours). Safety precautions are mandatory. The zinc coating also interferes with the weld unless you account for it.
Best Rods for Galvanized Steel
E6011
Best stick rod for welding galvanized steel. The cellulosic arc burns through the zinc coating and the slag helps float zinc contamination to the surface. Runs on AC or DCEP.
E6013
Acceptable for light galvanized material where the zinc layer is thin. The soft arc does not blast through zinc as aggressively as E6011, so more porosity may result on heavier galvanized coatings.
ER70S-6
MIG works on galvanized if you grind the zinc off the weld zone first. Without grinding, the zinc causes severe porosity and spatter. Significantly more prep work required compared to stick.
Quick Amperage Reference for Galvanized Steel
| Electrode | Polarity | Common Size | Amps | Full Chart |
|---|---|---|---|---|
| E6011 | AC / DCEP | 1/8" | 75-130A | E6011 chart |
| E6013 | AC / DCEP / DCEN | 1/8" | 70-120A | E6013 chart |
| ER70S-6 | DCEP | 0.035" | 50-220A | ER70S-6 chart |
Galvanized Steel Safety and Technique
CRITICAL SAFETY: Always weld galvanized steel with adequate ventilation or a supplied-air respirator. Position yourself upwind if outdoors. Standard cartridge respirators with P100 filters provide minimum protection. Supplied air is preferred for sustained work.
For best weld quality, grind the zinc coating off both sides of the joint for at least 1 inch beyond the weld zone. This eliminates zinc interference and fume generation. If you cannot grind, use E6011 with a longer arc length to let zinc fumes escape ahead of the puddle. Travel slightly slower to allow zinc to burn off before the puddle arrives. Expect more spatter than normal.
Which Rod for Your Situation
Equipment You Need
The welder matters less than the ventilation. A supplied-air respirator is the safest choice for sustained galvanized welding. At minimum, use a P100 cartridge respirator and work outdoors or with forced ventilation. A fan blowing fumes away from your breathing zone is not optional.
Mistakes to Avoid With Galvanized Steel
Welding galvanized steel in an enclosed space without ventilation. Zinc fume fever is debilitating and exposure is cumulative. Using E7018 on unground galvanized surface, which produces severe porosity because the low-hydrogen coating cannot handle the zinc contamination. Assuming the zinc coating provides corrosion protection after welding. The heat destroys the coating in the weld zone, requiring cold galvanizing paint on the finished weld.
What Goes Wrong
A fabricator welded galvanized fence panels indoors for a full shift using only a standard dust mask. By evening he had chills, fever, muscle aches, and nausea. Metal fume fever from zinc oxide kept him in bed for two days. The job took one day. The recovery took two. A supplied-air respirator costs less than one day of lost work.
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Reference data only. Verify all settings against manufacturer documentation and the applicable welding code before use. Amperage ranges are starting points that vary by position, fit-up, and material. Welding involves serious injury risks including burns, electric shock, fume exposure, and fire. This site does not replace proper training, certification, or employer safety procedures. See full terms of use.