Offshore structures in recent time are witnessing the increased application of dissimilar metal welds for enhanced structural integrity. Offshore structures are complex systems. Fabrication, maintenance, and repair of these structures require conventional and advanced welding technologies along with suitably chosen welding consumables. The present work aims at the design and development of shielded metal arc welding (SMAW) electrode coating using extreme vertices design methodology. This work also attempts to study weld metal chemistry along with microstructure and microhardness. Red ochre, a mineral waste from iron ore is added in the coating composition. Multi response optimization has been carried out to obtain optimum flux composition and to study the effect of individual constituents and their interactions on the weld chemistry and microhardness. © 2020 American Society of Mechanical Engineers (ASME). All rights reserved.