A Quick Guide to SMAW (Stick Welding)

In Calgary’s industrial, construction, and repair sectors, few welding processes are as reliable and versatile as SMAW—Shielded Metal Arc Welding, commonly known as stick welding. Whether you’re working on heavy equipment, structural steel, pipelines, farm machinery, or on-site repairs in difficult conditions, SMAW remains one of the most trusted welding methods in Alberta.

This comprehensive guide explores how SMAW works, best practices for strong structural welds, the most common electrode types, polarity differences, and where stick welding is used across Calgary’s residential, commercial, and industrial markets.

What Is SMAW (Stick Welding)?

SMAW (Shielded Metal Arc Welding) is a manual welding process that uses a flux-coated consumable electrode, commonly called a “stick rod.”
When the rod strikes the metal, it creates an electric arc that melts both the base metal and the electrode, forming a strong weld pool.

The key advantage of SMAW is that it does not require external shielding gas. Instead, the electrode’s flux coating releases gases and forms a protective slag that shields the weld from atmospheric contamination.

This makes stick welding extremely useful in locations where MIG or TIG welding cannot be used, such as:

  • Outdoor worksites
  • Windy conditions
  • Dirty environments
  • Remote areas
  • Industrial shutdown work

Why Stick Welding Is So Popular

Calgary’s diverse industries—including oil & gas, construction, heavy equipment, agricultural operations, manufacturing, and fabrication shops—rely heavily on SMAW because of its:

✔ Versatility

Works on steel, cast iron, stainless steel, hardfacing, pipelines, and heavy structural components.

✔ Portability

Only requires a welding machine and rods—no gas cylinders, hoses, or wire feeders.

✔ Performance Outdoors

Handles wind, moisture, and dirt much better than TIG or MIG.

✔ Deep Penetration

Many SMAW electrodes deliver strong, structural-grade penetration ideal for heavy steel.

✔ Cost-Efficiency

Equipment setup is simple, inexpensive, and easy to maintain.

How SMAW (Stick Welding) Works

Stick welding is simple in concept but requires skill, technique, and electrode knowledge to master. Here’s how the SMAW process works:

1. Power Source & Polarity

SMAW uses either:

  • AC (alternating current)
  • DCEP (direct current electrode positive)
  • DCEN (direct current electrode negative)

Electrode type determines the correct polarity. Rods like 7018 typically use DCEP, while rods like 6013 and 6011 may use AC or DC.

Correct polarity affects:

  • Arc stability
  • Penetration
  • Weld bead appearance
  • Spatter levels

2. Striking the Arc

The welder starts the arc using:

  • A tap technique, or
  • A scratch technique (like striking a match)

Once the arc starts, the rod and base metal melt into a controlled weld puddle.

3. Flux Coating Activation

The flux coating burns and produces:

  • Shielding gas → protects molten metal
  • Slag layer → solidifies on top of the weld
  • Arc stabilizers → regulate arc performance
  • Alloying elements → improve weld metal strength

This self-shielding feature is what makes SMAW ideal for outdoor and remote locations.

4. Weld Pool Formation

As the rod melts, it adds filler metal to the joint. The welder controls:

  • Rod angle
  • Travel speed
  • Arc length
  • Heat input
  • Puddle size

Proper technique creates a smooth, strong weld.

5. Slag Removal

Once the weld cools slightly, the slag is removed with:

  • A chipping hammer
  • A wire brush

Removing slag reveals the finished bead and prepares the surface for additional weld passes.

Best Practices for Strong, Clean SMAW Welds

Professional welders follow strict techniques to ensure structural integrity and aesthetic weld quality:

🔧 Maintain the right arc length

Too long → spatter, undercut, porosity
Too short → sticking, unstable arc

🔧 Use the correct rod angle

Typically 10–15° drag angle depending on joint type.

🔧 Control travel speed

Slow = excessive buildup
Fast = poor penetration

🔧 Keep electrodes dry

Moisture causes porosity and hydrogen cracking.
Rods like 7018 should be stored in a rod oven.

🔧 Prep the metal properly

Although SMAW tolerates dirt better than TIG/MIG, cleaner metal always results in stronger welds.

🔧 Match amperage to the rod diameter

Example amperage ranges:

  • 1/8″ 7018: 90–140 amps
  • 1/8″ 6010: 70–120 amps

Common SMAW Electrode Types and Their Applications

SMAW rods vary widely in performance. Here are the most common electrodes used in Calgary fabrication and repair work:

E6010 – Deep Penetrating Pipe & Root Pass Rod

Good for:

  • Root passes
  • Pipeline welding
  • Dirty, rusty metal
  • Out-of-position welding

Advantages:

  • Fast-freeze puddle
  • High penetration
  • Great for vertical and overhead

E6011 – AC-Compatible Version of 6010

Good for:

  • Farm equipment
  • Maintenance welding
  • Sheet metal repairs
  • AC welders

Advantages:

  • Works on AC machines
  • Good for beginners
  • Great on dirty steel

E6013 – Smooth, Clean Beads

Common uses:

  • General fabrication
  • Thin metal
  • Fencing
  • Automotive sheet metal

Advantages:

  • Soft, stable arc
  • Minimal spatter
  • Cleaner weld appearance

E7018 – Low Hydrogen Structural Rod

The most popular rod in Calgary construction.
Used for:

  • Structural steel
  • Heavy equipment
  • Buildings and bridges
  • High-strength applications
  • Pressure vessels

Advantages:

  • Smooth bead profile
  • Strong, low-hydrogen weld
  • Excellent for critical welds

Note: Must be kept dry—requires rod oven storage.

E7024 – High-Deposition Iron Powder Rod

Used for:

  • Long flat welds
  • Fillet welds
  • High-production work

Advantages:

  • Extremely high deposition rate
  • Heavy, smooth weld beads

Common Applications of Stick Welding

SMAW is used daily across Calgary’s trades, fabrication shops, and industrial operations because it excels where other processes struggle.

1. Heavy Equipment Repair

Ideal for:

  • Excavator buckets
  • Loader arms
  • Dozer blades
  • Frames and booms
  • Hardfacing applications

SMAW’s penetration and outdoor reliability make it perfect for field repairs.

2. Oil & Gas and Pipeline Work

Stick welding is a standard in Alberta’s energy sector for:

  • Pipeline construction
  • Station repairs
  • Pressure piping
  • Facility maintenance

Rods like 6010 and 7018 dominate this category.

3. Structural Steel and Construction

Used for:

  • I-beams
  • Columns
  • Stair stringers
  • Support frames
  • Building erection

Low-hydrogen rods provide the strength required for engineered steel structures.

4. Fabrication & Manufacturing

Stick welding is useful in shop environments for:

  • Brackets
  • Heavy frames
  • Machinery bases
  • Industrial components

5. Farm, Ranch, and Rural Welding

Perfect for:

  • Fencing
  • Implements
  • Trailers
  • Gates
  • Repair work

SMAW is reliable even in mud, wind, and low-visibility environments.

6. Cast Iron Welding

Specialized electrodes allow stick welding to repair:

  • Engine blocks
  • Machinery housings
  • Brackets and mounts

Why Calgary Businesses Trust SMAW Welding Services

SMAW remains a cornerstone of welding because it offers:

  • Strong, deep penetrating welds
  • Excellent performance outdoors
  • Versatility for multiple metals
  • Highly portable equipment
  • Cost-effective, dependable repairs

For heavy-duty work where reliability matters, stick welding is still one of the most trusted welding processes available.

Need SMAW Welding Services in Calgary? We’re Here to Help

Whether you’re dealing with:

  • Structural welding
  • Heavy equipment repairs
  • On-site field welding
  • Farm machinery repairs
  • Industrial maintenance
  • Pipeline work
  • Stick welding fabrication

Professional SMAW services ensure your steel structures and equipment receive durable, code-compliant welds that last.