Weld Cost Calc XL

Legal Statement Year 2006 release Copyright © 2006 Mark F. Mruczek

Terms This software was developed by Mark F. Mruczek f you use this product you agree to the followi!g ter"s a!d co!ditio!s# $ The user uses this this software software at their ow! ow! risk. 2 This !otice !otice "ust be i!cluded i!cluded with with all copies "ade. "ade. % This product is used &as is& without without warra!tees or liability liability. t is your respo!sibility to k!ow how to use this software. '!y (ob)weld"e!t *uoted with with this software is the users respo!sibility. respo!sibility. Mruczek+s ,eldi!g -!gi!eeri!g does !ot guara!tee the accuracy of this product.  'll risk associated associated with this products use is assu"ed by the user. user. / 'll cost calculated with this spreadsheet are for weldi!g weldi!g o!ly. o!ly. t does !ot take i!to co!sideratio! "achi!i!g cost "aterial cost 1other tha! weldi!g "aterial

Changes To Spreadsheet f you "ake a!y cha!ges to this spreadsheet you are respo!sible for a!y a!d all cha!ges that you "ake.

Comments f you have co""e!ts correctio!s or *uestio!s abo ut this product se!d a! e"ail to ""ruczek3atla!ticbb.!et.  will try to a!swer all e4"ails i! a ti"ely "a!!er. ""ruczek3atla!ticbb.!et

Verification This progra" was verified the followi!g ways $ 5a!d 5a!d calculat calculatio! io!s s 2 Co"pariso! with with other co""ercial software software a!d publicatio!s publicatio!s 'lthough every effort effort was "ade to "ake this software software as accurate a!d easy to u!dersta!d u!dersta!d as possible there is !o way to guara!tee it+s accuracy. There are assu"ptio!s that "ust be "ade co!cer!i!g welder a!d process efficie!cy. efficie!cy. rocess efficie!cy is built i!to the progra" a!d the i!for"atio! was obtai!ed fro" !u"erous publicatio!s. ,elder efficie!cy is supplied by the user. This is o!e of the "ost basic factors i! the cost calculatio!s a!d "ust be deter"i as accurately as possible i! order to "ake sou!d evaluatio!s of weldi!g cost.

Welder Efficiency Welder Efficiency " ,elder -fficie!cy is the perce!tage of a welder8s worki!g day that is actually spe!t weldi!g. ' /7 1./ operati!g factor "ea!s that o!ly /7 of the welder8s day is actually spe!t weldi!g weldi!g 1. hrs. The bala!ce of ti is spe!t i!stalli!g a !ew electrode or wire clea!i!g slag positio!i!g the weld"e!t clea!i!g spatter fro" the weldi!g gu! prepari!g the (oi!t "ovi!g "ovi!g parts coffee break etc. f the actual operati!g factor is is !ot k!ow! the followi!g followi!g averages ca! b used. %07 "ay be used with the shielded "etal arc weldi!g process19M', /07 "ay be used with the :as "etal arc weldi!g process 1:M', /7 "ay be used with the Flu;Cored 'rc ,eldi!g process 1FC', /74/07 "ay be used with the 9ub"erged 'rc ,eldi!g process 19', /07 "ay be used with a!y auto"atic ,eldi!g process

Labor and Oerhead !ates
,eld shops i! "a!ufacturi!g pla!ts !or"ally have established labor a!d overhead rates for each depart"e!t.
Weld #oint $ra%ings All weld joint drawings were produced usign Arc Works Software Software developed and distributed by Lincoln Electric C Copyright © !!" Lincoln Electric Co#pany

,eld shops i! "a!ufacturi!g pla!ts !or"ally have established labor a!d overhead rates for each depart"e!t.
Weld #oint $ra%ings All weld joint drawings were produced usign Arc Works Software Software developed and distributed by Lincoln Electric C Copyright © !!" Lincoln Electric Co#pany

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WELD COST CALC XL - MAIN MENU &lease Select The Type of Weld #oint Yo' Wish To Eal'ate by &ointing to and Clic(ing on The )ppropriate #oint $esign *elo%

FILLET WELD

SINGLE - V GROOVE

>ouble ?evel

Co"pou!d 9i!gle4?evel

DOUBLE-V GROOVE

9i!gle4A

9i!gle4@

SINGLE BEVEL

>ouble4A

=verlay ) 9urfaci!g

>ouble4@

$eposition !ate Calc'lations )nd Wire +eed !ate Metric Units English Units &lease choose 'nits before yo' enter data into the fields belo% B=C-99 GMAW D7 (Spray) GMAW67 (75Ar-25CO @se this worksheet to deter"i!e the wire

C=E9@M'?<-#

-B$T4$

!co 622

,ire >ia"eter 1i!

0.0/

0.0/

it takes to feed a give! le!gth of wire.

Ti"e ,ire Fed1 sec
$/.00 .00

$6.DD /2.%/

,-. 9et the wire feed co!trol to the desired locatio! to achive the ,9 a"ps

Filler Metal Type

Carbon Steel 0.2D

,ire Feed Bate :M', 19pray For >ep Bate For

:M', 19pray

Nickel0.%$0 Alloy

a!d depositio! rate by "easuri!g the ti"e

2-. Cut the weldi!g electrode flush with the e!d of the co!tact tube.

%$6.00

i!)"i!

/-. ress the weldi!g trigger 1or Aog co!trol

D.%D

lb)hr

o! the wire feeder. 'llow the wire to feed while ti"i!g.

$eposition !ate Calc'lations )nd Wire +eed !ate Metric Units English Units &lease choose 'nits before yo' enter data into the fields belo% B=C-99 GMAW D7 (Spray) GMAW67 (75Ar-25CO @se this worksheet to deter"i!e the wire

C=E9@M'?<-#

-B$T4$

!co 622

,ire >ia"eter 1i!

0.0/

0.0/

it takes to feed a give! le!gth of wire.

Ti"e ,ire Fed1 sec
$/.00 .00

$6.DD /2.%/

,-. 9et the wire feed co!trol to the desired locatio! to achive the ,9 a"ps

Filler Metal Type

Carbon Steel 0.2D

,ire Feed Bate :M', 19pray For >ep Bate For

:M', 19pray

Nickel0.%$0 Alloy

a!d depositio! rate by "easuri!g the ti"e

2-. Cut the weldi!g electrode flush with the e!d of the co!tact tube.

%$6.00

i!)"i!

/-. ress the weldi!g trigger 1or Aog co!trol

D.%D

lb)hr

o! the wire feeder. 'llow the wire to feed while ti"i!g.

,ire Feed Bate :M', 1/'r42/C=2 For >ep Bate For :M', 1/'r42/C=2

>epositio! Bate Calculatio!

$D6.$

i!)"i!

/.2

lb)hr

-. 9top the wire feed a!d stop watch at the

9a"e ti"e. 1-. Measure the le!gth of wire feed a!d e!ter i!to the sheet as well as the ti"e

2

D rate

 wire dia 

π⋅

2

⋅wire speed ⋅ρ ⋅E

rocess efficie!cy 1- is based o! the process type a!d describes how "a!y pou!ds of weld "etal ca! be e;pected fro" a give! weight of the electrode or weldi!g wire purchased. 's a! e;a"ple $00 pou!ds of a flu; cored electrode with a! efficie!cy of D/7 will produce appro;i"ately D/ pou!ds of weld "etal whereas $00 pou!ds of shielded4"etal4arc electrode with a! efficie!cy of 6/7 will produce appro;i"ately 6/ pou!ds of weld "etal

@!its G
$ $

DETERMINING WELDING COST FOR A FILLET WELD

Mark Mruczek 9e!ior ,eldi!g -!gi!eer Mruczek ,eldi!g -!gi!eeri!g

&ro>ect3 T'be to ?eader Welds Cost Company3 C@ : E&T@ S'b>ect3 Welding Cost A Time Welding process7es. 9sed3 8T)W

*ase aterial3 CS &rod'ct +orm3 &ipe +iller aterial E!40S"6 Trade 5ame3

&lease choose 'nits before yo' enter data into the fields belo% &rocess , 0.%/ i! Leg Sie 7in. +iller material 0 Carbon Steel &rocess 8as 9sed )mps Volts Wire +eed 7in:min. Electrode $iam- 7in. Total Length of Weld 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr. Welder Efficiency Cost Electrode 7<:lb. Labor:Oerhead !ate Cost of 8as 8as Cylinder Sie 7ft;/. &o%er Cost Cost of +l'= 7<:lb.

GTAW

Choose Units For This Sh...

English Units

Leg Sie 7in. +iller material

0

&rocess 8as 9sed

Ar

$$0 $/ 0 0.0%/ 0.6/ 2.0 %/

0/)$)0 $ of 2

$ate3 &age3

' H i!)"i! i! ft i!)"i! ftI%)hr

30%

Metric Unit

&rocess 2 0.%/ i! 0 Carbon Steel GTAW

0

Ar

)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. Total Length of Weld 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr.

$$/ $/ 0 0.0%/ 0.6/ 2.% %/

Welder Efficiency

30%


2.62 J)lb 2.62 J)lb Cost Electrode 7<:lb. /0 J)hr /0.00 J)hr Labor:Oerhead !ate %0.00 J)bottle %0.00 J)bottle Cost of 8as %%0 ftI% %%0.00 ftI% 8as Cylinder Sie 7ft;/. 0.20 J)kwh 0.20 J)kwh &o%er Cost 4 J)lb 4 J)lb Cost of +l'= 7<:lb. Leg Sie" The leg size show! above is what is re*uired. For cost calculatio!s $07 is added to the size show!. This is co!sista!t with !or"al shop practices. ! other words welders will typically produce a weld that is $07 larger tha! what is re*uired. Fillet welds are assu"ed to be co!ve; rather tha! flat for cost calculatio!s 19ee >rawi!gs to the right. @!its G
$ $

Scroll $own %o See &esults

Flat

Co!ve;

WELDING COST OUTPUT FOR A FILLET WELD

O9T&9T +O! Err3102
WELDING COST OUTPUT FOR A FILLET WELD

O9T&9T +O! Err3102
BV)L9E &roides )

BV)L9E

Saings !elatie To The BV)L9E


BV)L9E


DETERMINING WELDING COST FOR A SINGLE-BEVEL GROOVE WELD

*ase aterial3 &rod'ct +orm3 +iller aterial S'b>ect# ?eader $iision &late C'rrent $esign ?& Econ Welding process7es. 9sed3 S)W : +C)W Trade 5ame3 5otes3 process , D root pass process 2 D +ill and cap passes

Mark Mruczek ,eldi!g -!gi!eer Mruczek ,eldi!g -!gi!eeri!g Aoh!stow! ' $/0/

&ro>ect3 Weld Cost Comparison Company3

&lease choose 'nits before yo' enter data into the fields belo% &rocess , S)W !oot &ass 0.0% i! Thic(ness 7in. 0.0% i! ?eight of FhF 7in. !oot Opening 7in. 0.0% i! !oot +ace7in. 0.0%0 i! +iller material &rocess 8as 9sed )mps Volts Wire +eed 7in:min. Electrode $iam- 7in. #oint )ngle Total Weld Length 7f t. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr.

Carbon Steel SMAW (12" Stick) N/A

/ 20 0 0.0%/ /0 2.2 / 0

' H i!)"i! i! deg ft

i!)"i! ftI%)h

4

$ate3 ipe)late &age3 -B$T4$ Choose Units For This She...
$2)$)06 $ of 2 English Units

Metric Units

&rocess 2 +C)W +ill &asses 0.D0/ Thic(ness 7in. 0.0% ?eight of FhF 7in. !oot Opening 7in. 0.0% !oot +ace7in. 0.0%

i! i! i! i!

+iller material &rocess 8as 9sed

Carbon Steel

)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. #oint )ngle Total Weld Length 7f t. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr.

26/ 2D %20 0.0/ /0 2.D$ $0 %/

FCAW (Gas) 75Ar-25C02


i!)"i! ftI%)h

DETERMINING WELDING COST FOR A SINGLE-BEVEL GROOVE WELD

*ase aterial3 &rod'ct +orm3 +iller aterial S'b>ect# ?eader $iision &late C'rrent $esign ?& Econ Welding process7es. 9sed3 S)W : +C)W Trade 5ame3 5otes3 process , D root pass process 2 D +ill and cap passes


&ro>ect3 Weld Cost Comparison Company3

&lease choose 'nits before yo' enter data into the fields belo% &rocess , S)W !oot &ass 0.0% i! Thic(ness 7in. 0.0% i! ?eight of FhF 7in. !oot Opening 7in. 0.0% i! !oot +ace7in. 0.0%0 i! +iller material &rocess 8as 9sed )mps Volts Wire +eed 7in:min. Electrode $iam- 7in. #oint )ngle Total Weld Length 7f t. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr. Welder Efficiency Cost Electrode 7<:lb. Labor !ate Cost of 8as 8as Cylinder Sie 7ft;/. &o%er Cost Cost of +l'= 7<:lb.

@!its G
4

$ate3 ipe)late &age3 -B$T4$ Choose Units For This She...
Carbon Steel

)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. #oint )ngle Total Weld Length 7f t. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr. Welder Efficiency Cost Electrode 7<:lb. Labor !ate Cost of 8as:bottle 8as Cylinder Sie 7ft;/. &o%er Cost

26/ 2D %20 0.0/ /0 2.D$ $0 %/

N/A


i!)"i! ftI%)hr

35%

J)lb J)hr J)bottle ftI% J)kwh


i! i! i! i!


SMAW (12" Stick)

2./$ 60.00 4 0 0.20 4 $ $

Metric Units

English Units

&rocess 2 +C)W +ill &asses 0.D0/ Thic(ness 7in. 0.0% ?eight of FhF 7in. !oot Opening 7in. 0.0% !oot +ace7in. 0.0%

Carbon Steel

/ 20 0 0.0%/ /0 2.2 / 0

$2)$)06 $ of 2

Cost of +l'= 7<:lb.

FCAW (Gas) 75Ar-25C02


i!)"i! ftI%)hr

45%

%.00 60.00 0.00 %%0.00 0.20 4

J)lb J)hr J)bottle ftI% J)kwh J)lb

WELDING COST OUTPUT FOR A SINGLE-BEVEL GROOVE WELD

O9T&9T +O! &rocess , S)W !oot &ass '"ou!t of filler "etal !eeded H'<@-N lbs Eu"ber of passes per (oi!t K H'<@-N '"ou!t of shieldi!g gas H'<@-N ftI% Eu"ber :as ?ottles Be*uired E)' 'ctual weldi!g ti"e H'<@-N hr >epositio! Bate H'<@-N lb)hr

WELDING COST OUTPUT FOR A SINGLE-BEVEL GROOVE WELD

O9T&9T +O! &rocess , S)W !oot &ass '"ou!t of filler "etal !eeded H'<@-N lbs Eu"ber of passes per (oi!t K H'<@-N '"ou!t of shieldi!g gas H'<@-N ftI% Eu"ber :as ?ottles Be*uired E)' 'ctual weldi!g ti"e H'<@-N hr >epositio! Bate H'<@-N lb)hr epositio! Bate H'<@-N lb)hr

,eldi!g -lectrode Cos t $007

BV)L9E

DETERMINING WELDING COST FOR A DOUBLE-BEVEL GROOVE WELD

Mark Mruczek 9e!ior ,eldi!g -!gi!eer

ro(ect# Co"pa!y# 9ub(ect# ,eldi!g Cost Co"pariso! :M',4 vs 9', ,eldi!g process1es @sed# :M',4

&lease choose 'nits before yo' enter data into the fields belo% &rocess , ./ "" Thic(ness 7in. 2./ "" Cap ?eight FhF7in. 2./ "" !oot ?eight FhF7in. 0 "" !oot Opening 7in. $./ "" !oot +ace7in.  "" $epth of *eel 7$,. +iller material &rocess 8as 9sed )mps Volts Wire +eed 7m:min. Electrode $iam- 7mm. *eel )ngle Top Side *eel )ngle *ac( Total Weld Length 7m.

Carbon Steel MCAW 95Ar-5Co2

2/0 26 6.D/ $.$% / / 6

' H ")"i! "" deg deg "

?ase Material# 59<'4D0 roduct For"# late Filler Material M<4$009 Trade Ea"e#

>ate# age#

0%)22)06 $ of 2

Choose Units For This She...

English Units

Thic(ness 7in. Cap ?eight FhF7in. !oot ?eight FhF7in. !oot Opening 7in. !oot +ace7in. $epth of *eel 7$,. +iller material

&rocess 2 $2 "" 2./ "" 2./ "" 0 ""  "" 6 "" Carbon Steel

&rocess

SAW

8as 9sed

N/A

)mps Volts Wire +eed 7m:min. Electrode $iam- 7mm. *eel )ngle Top Side *eel )ngle *ac( Total Weld Length 7m.

Metric Units

2/ %/ .2 2 / / $2.$2

' H ")"i! "" deg deg "

DETERMINING WELDING COST FOR A DOUBLE-BEVEL GROOVE WELD


ro(ect# Co"pa!y# 9ub(ect# ,eldi!g Cost Co"pariso! :M',4 vs 9', ,eldi!g process1es @sed# :M',4

?ase Material# 59<'4D0 roduct For"# late Filler Material M<4$009 Trade Ea"e#

&lease choose 'nits before yo' enter data into the fields belo% &rocess , ./ "" Thic(ness 7in. 2./ "" Cap ?eight FhF7in. 2./ "" !oot ?eight FhF7in. 0 "" !oot Opening 7in. $./ "" !oot +ace7in.  "" $epth of *eel 7$,. +iller material &rocess 8as 9sed )mps Volts Wire +eed 7m:min. Electrode $iam- 7mm. *eel )ngle Top Side *eel )ngle *ac( Total Weld Length 7m. Trael Speed 7m:min. 8as +lo% !ate 7L:min. Welder Efficiency Cost Electrode 7<:(g. Cost of +l'= 7<:(g. Labor !ate 7<:hr. 8as Cost7per bottle. 8as Cylinder Sie 7m;/. &o%er Cost

@!its G
>ate# age#

0%)22)06 $ of 2



Carbon Steel

95Ar-5Co2

' H ")"i! "" deg deg " ")"i! <)"i!

$0.D 4 //.00 0.00 .%2D 0.$D 2 2

J)kg J)kg J)hr J)bottle "I% J)kwh

35%


Carbon Steel SAW

8as 9sed

N/A

)mps Volts Wire +eed 7m:min. Electrode $iam- 7mm. *eel )ngle Top Side *eel )ngle *ac( Total Weld Length 7m. Trael Speed 7m:min. 8as +lo% !ate 7L:min. Welder Efficiency Cost Electrode 7<:(g. Cost of +l'= 7<:(g. Labor !ate 7<:hr. 8as Cost7per bottle. 8as Cylinder Sie 7m;/. &o%er Cost

Metric Units

&rocess 2 $2 "" 2./ "" 2./ "" 0 ""  "" 6 ""

&rocess

MCAW

2/0 26 6.D/ $.$% / / 6 0.266 $

English Units

2/ ' %/ H .2 ")"i! 2 "" / deg / deg $2.$2 " 0.06 ")"i! 0 <)"i! 40%

$0.$ D./ //.00 4 0 0.$D

J)kg J)kg J)hr J)bottle "I% J)kwh

WELDING COST OUTPUT FOR A DOUBLE-BEVEL GROOVE WELD

O9T&9T +O! C)W '"ou!t of filler "etal !eeded '"ou!t of Flu; !eeded Eu"ber of passes per (oi!t K '"ou!t of shieldi!g gas used Eu"ber :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate
J

H'<@-N kg 0.00 kg H'<@-N H'<@-N "I% H'<@-N H'<@-N hrs H'<@-N kg)hr H'<@-N H'<@-N 4 H'<@-N H'<@-N H'<@-N BV)L9E H'<@-N J)" H'<@-N J)" 4 J)" H'<@-N J)" H'<@-N J)" H'<@-N kg welded i! D hr H'<@-N kg H'<@-N kg

< ab or C os t

,e ld i! g -l ec tro de Co st

:as Cost

ower Cos t

,eldi!g -lectrode Cost

Flu; Cost

:as Cost

Fl u; C os t

ower Cost

WELDING COST OUTPUT FOR A DOUBLE-BEVEL GROOVE WELD

O9T&9T +O! C)W '"ou!t of filler "etal !eeded '"ou!t of Flu; !eeded Eu"ber of passes per (oi!t K '"ou!t of shieldi!g gas used Eu"ber :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate
J

H'<@-N kg 0.00 kg H'<@-N H'<@-N "I% H'<@-N H'<@-N hrs H'<@-N kg)hr H'<@-N H'<@-N 4 H'<@-N H'<@-N H'<@-N BV)L9E H'<@-N J)" H'<@-N J)" 4 J)" H'<@-N J)" H'<@-N J)" H'<@-N kg welded i! D hr

O9T&9T +O! S)W '"ou!t of filler "etal !eeded H'<@-N kg '"ou!t of Flu; !eeded H'<@-N kg Eu"ber of passes per (oi!t K H'<@-N '"ou!t of shieldi!g gas used H'<@-N "I% Eu"ber :as ?ottles Be*uired E)' 'ctual weldi!g ti"e H'<@-N hr >epositio! Bate H'<@-N kg)hr

BBB

< ab or C os t

,e ld i! g -l ec tro de Co st

:as Cost

ower Cos t

,eldi!g -lectrode Cost

Flu; Cost

:as Cost

Fl u; C os t

ower Cost

40%

DETERMINING WELDING COST FOR A COMPOUND SINGLE-BEVEL GROOVE WELD


&ro>ect3 Weld Cost Comparison *ase aterial3 Company3 &rod'ct +orm3 S'b>ect# ?eader Endplate ?& ECO5 5e% $esign +iller aterial Welding process7es. 9sed3 S)W :+C)W Trade 5ame3 5otes3 process , D root pass process 2 D +ill and cap passes

&lease choose 'nits before yo' enter data into the fields belo% &rocess , 0.D2/$ i! Thic(ness 0.0%/ i! ?eight of FhF 0.$6D/0% i! !oot Opening 0.0622$% i! !oot +ace 0./ i! $epth of root *eel +iller material

Carbon Steel

&rocess 8as 9sed

FCAW (Gas)

)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. !oot )ngle 7deg. +inal )ngle 7deg. Total Weld Length 7ft.

ipe ) late -$T4$
>ate# age#

$2)$)06 $ of 2


English Units

Thic(ness ?eight of FhF !oot Opening !oot +ace $epth of root *eel +iller material &rocess 8as 9sed

75Ar-25C02

2/ 2D %%0 0.0/2 %0 $0 2.D$

C9

' H i!)"i! i! deg deg ft

)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. !oot )ngle 7deg. +inal )ngle 7deg. Total Weld Length 7ft.

Metric Units

&rocess 2 0.D2/ i! 0.0%/ i! 0.$6D/ i! 0.062 i! 0./ i! Carbon Steel GMAW (Spray) 95Ar-5Co2

2/ ' %2 H 200 i!)"i! 0.0/2 i! %0 deg $0 deg 2.D$ ft

DETERMINING WELDING COST FOR A COMPOUND SINGLE-BEVEL GROOVE WELD


&ro>ect3 Weld Cost Comparison *ase aterial3 Company3 &rod'ct +orm3 S'b>ect# ?eader Endplate ?& ECO5 5e% $esign +iller aterial Welding process7es. 9sed3 S)W :+C)W Trade 5ame3 5otes3 process , D root pass process 2 D +ill and cap passes

&lease choose 'nits before yo' enter data into the fields belo% &rocess , 0.D2/$ i! Thic(ness 0.0%/ i! ?eight of FhF 0.$6D/0% i! !oot Opening 0.0622$% i! !oot +ace 0./ i! $epth of root *eel +iller material

Carbon Steel

&rocess 8as 9sed

FCAW (Gas)

Welder Efficiency Cost Electrode 7<:lb. Cost of +l'= 7<:lb. Labor !ate 7<:hr. 8as Cost7per bottle. 8as Cylinder Sie 7ft;/. &o%er Cost

@!its G

ipe ) late -$T4$
>ate# age#

$2)$)06 $ of 2


English Units

Thic(ness ?eight of FhF !oot Opening !oot +ace $epth of root *eel +iller material &rocess 8as 9sed

75Ar-25C02

2/ 2D %%0 0.0/2 %0 $0 2.D$ $0./ %/

' H i!)"i! i! deg deg ft i!)"i! ftI%)hr

%.00 4 60.00 0.00 %%0.00 0.20 $

J)lb J)lb J)hr J)bottle ftI% J)kwh
)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. !oot )ngle 7deg. +inal )ngle 7deg. Total Weld Length 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr.

C9

)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. !oot )ngle 7deg. +inal )ngle 7deg. Total Weld Length 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr.

45%


Welder Efficiency Cost Electrode 7<:lb. Cost of +l'= 7<:lb. Labor !ate 7<:hr. 8as Cost7per bottle. 8as Cylinder Sie 7ft;/. &o%er Cost

Metric Units

&rocess 2 0.D2/ i! 0.0%/ i! 0.$6D/ i! 0.062 i! 0./ i! Carbon Steel GMAW (Spray) 95Ar-5Co2

2/ ' %2 H 200 i!)"i! 0.0/2 i! %0 deg $0 deg 2.D$ ft $$ i!)"i! 0 ftI%)hr 45%

2.2/ $./0 /0.00 0.00 %%0 0.$/


$

WELDING COST OUTPUT FOR A COMPOUND SINGLE-BEVEL GROOVE WELD

O9T&9T +O! +C)W 78as. '"ou!t of filler "etal !eeded '"ou!t of Flu; !eeded Eu"ber of passes per (oi!t K '"ou!t of shieldi!g gas Eu"ber of :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate
H'<@-N 0.00 H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N 4 H'<@-N H'<@-N H'<@-N BV)L9E H'<@-N H'<@-N 4 H'<@-N H'<@-N H'<@-N

O9T&9T +O! 8)W 7Spray. '"ou!t of filler "etal !eeded '"ou!t of Flu; !eeded

H'<@-N lbs H'<@-N lbs

lbs lbs

ftI% bottles hr lb)hr

Flu; Cost :as Cost ower Cost

J)ft J)ft J)ft J)ft J)ft lb welded i! D hr

WELDING COST OUTPUT FOR A COMPOUND SINGLE-BEVEL GROOVE WELD

O9T&9T +O! +C)W 78as. '"ou!t of filler "etal !eeded '"ou!t of Flu; !eeded Eu"ber of passes per (oi!t K '"ou!t of shieldi!g gas Eu"ber of :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate
H'<@-N 0.00 H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N 4 H'<@-N H'<@-N H'<@-N BV)L9E H'<@-N H'<@-N 4 H'<@-N H'<@-N H'<@-N

O9T&9T +O! 8)W 7Spray. '"ou!t of filler "etal !eeded '"ou!t of Flu; !eeded Eu"ber of passes per (oi!t K '"ou!t of shieldi!g gas Eu"ber of :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate
H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N BV)L9E H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N


BV)L9E

lbs lbs

ftI% bottles hr lb)hr

Flu; Cost :as Cost ower Cost


lbs lbs

ftI%

Flu; Cost

hr lb)hr

ow er Cost

:as Cost


Saings !elatie To The

BBB


BV)L9E


GMAW (Spray)

BBB

GMAW (Spray)

DETERMINING WELDING COST FOR A SINGLE-V GROOVE WELD

Mark Mruczek 9e!ior ,eldi!g -!gi!eer CTC Aoh!stow! ' $/0/

&ro>ect3 8)W To% *ars Company3 9tility Tool A Trailer S'b>ect# To% *ar Welding Cost Welding process7es. 9sed3 8T)W

?ase Material# roduct For"# Filler Material Trade Ea"e#

C9 Tube)?ar -B0942
>ate# age# Choose Units For This She...

0%)0)0 $ of 2 English Units

Metric Unit

5otes3

&lease choose 'nits before yo' enter data into the fields belo% &rocess , 0.%/ i! Thic(ness 7in. 0.$2/ i! ?eight of FhF 7in. 0.$2/ i! !oot Opening 7in. 0.0000 i! !oot +ace7in. +iller material &rocess 8as 9sed )mps Volts Wire +eed 7in:min. Electrode $iam- 7in. #oint )ngle 7deg. Total Weld Length 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr.

Carbon Steel GTAW 98Ar-2O2

$00 $/ 22/ 0.0/ %./ .00 $$ %/


i!)"i! ftI%)hr

&rocess 2 Thic(ness 7in. ?eight of FhF 7in. !oot Opening 7in. !oot +ace7in.

2 0.$2/ 0.$2/ 0.0000

i!

i! i! i!


Carbon Steel

)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. #oint )ngle 7deg. Total Weld Length 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr.

200 26 22/ 0.0/ %./ .00  %/

SMAW (12" Stick) N/A


i!)"i! ftI%)hr

DETERMINING WELDING COST FOR A SINGLE-V GROOVE WELD

Mark Mruczek 9e!ior ,eldi!g -!gi!eer CTC Aoh!stow! ' $/0/

&ro>ect3 8)W To% *ars Company3 9tility Tool A Trailer S'b>ect# To% *ar Welding Cost Welding process7es. 9sed3 8T)W

?ase Material# roduct For"# Filler Material Trade Ea"e#

C9 Tube)?ar -B0942
>ate# age#

0%)0)0 $ of 2


English Units

Metric Unit

5otes3

&lease choose 'nits before yo' enter data into the fields belo% &rocess , 0.%/ i! Thic(ness 7in. 0.$2/ i! ?eight of FhF 7in. 0.$2/ i! !oot Opening 7in. 0.0000 i! !oot +ace7in. +iller material &rocess 8as 9sed )mps Volts Wire +eed 7in:min. Electrode $iam- 7in. #oint )ngle 7deg. Total Weld Length 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr. Welder Efficiency Cost Electrode 7<:lb. Labor !ate Cost of 8as 8as Cylinder Sie 7ft;/. &o%er Cost Cost of +l'= 7<:lb.

@!its G
&rocess 2 Thic(ness 7in. ?eight of FhF 7in. !oot Opening 7in. !oot +ace7in.

Carbon Steel

ft

i!)"i! ftI%)hr

15%

2.%0 /0.00 0.00 %%0 0.20 4 $ 2



)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. #oint )ngle 7deg. Total Weld Length 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr. Welder Efficiency Cost Electrode 7<:lb. Labor !ate Cost of 8as 8as Cylinder Sie 7ft;/. &o%er Cost

200 26 22/ 0.0/ %./ .00  %/

Cost of +l'= 7<:lb.

@!its G
SMAW (12" Stick) N/A

O9T&9T +O! &rocess 2 S)W 7,2F Stic(. '"ou!t of filler "etal !eeded H'<@-N lbs Eu"ber of passes per (oi!t K H'<@-N '"ou!t of shieldi!g gas H'<@-N ftI%

,eldi!g -lectrode Cos t

Flu; Cost

ower Cost


2.%0 /0.00 0.00 %%0.00 0.20 4 $

:as Cos t

:as Cos t


i!)"i! ftI%)hr

15%

WELDING COST OUTPUT FOR A SINGLE-V GROOVE WELD

O9T&9T +O! &rocess , 8T)W '"ou!t of filler "etal !eeded H'<@-N lbs Eu"ber of passes per (oi!t K H'<@-N '"ou!t of shieldi!g gas H'<@-N ftI% Eu"ber of :as ?ottles Be*uired H'<@-N 'ctual weldi!g ti"e H'<@-N hr >epositio! Bate H'<@-N lb)hr
i! i! i!

Carbon Steel

98Ar-2O2

' H i!)"i! i! deg

i!


GTAW

$00 $/ 22/ 0.0/ %./ .00 $$ %/

2 0.$2/ 0.$2/ 0.0000

Flu; Cos t


WELDING COST OUTPUT FOR A SINGLE-V GROOVE WELD

O9T&9T +O! &rocess , 8T)W '"ou!t of filler "etal !eeded H'<@-N lbs Eu"ber of passes per (oi!t K H'<@-N '"ou!t of shieldi!g gas H'<@-N ftI% Eu"ber of :as ?ottles Be*uired H'<@-N 'ctual weldi!g ti"e H'<@-N hr >epositio! Bate H'<@-N lb)hr epositio! Bate H'<@-N lb)hr


Flu; Cost

ower Cost


:as Cos t

ower Cost

&E!+O!)5CE )5$ COST CO&)!@SO5S $2.00

$0.00

D.00

6.00

.00

2.00

:as Cos t

rocess $ rocess 2

Flu; Cos t

&E!+O!)5CE )5$ COST CO&)!@SO5S $2.00

$0.00

D.00

6.00

rocess $ rocess 2

.00

2.00

0.00

9hift roductivity

>epositio! Bate

Carbon Steel SMAW (12" Stick)

Total cost per ft of weld

Carbon Steel SMAW (12" Stick)

15%

DETERMINING WELDING COST FOR A DOUBLE-V GROOVE WELD

Mark Mruczek ,eldi!g -!gi!eer

ro(ect# Co"pa!y# 5S!& 9ub(ect#

,eldi!g Cost

,eldi!g process1es C,F 9',

&lease choose 'nits before yo' enter data into the fields belo% &rocess , 2 i! Thic(ness 7in. 0.$2/ i! Cap ?eight FhF7in. 0.$2/ i! !oot ?eight FhF7in. 0.000 i! !oot Opening 7in. 0.$/0 i! !oot +ace7in. 0.2/ i! $epth of *eel 7$,. +iller material

Carbon Steel

?ase Material# 59<'46/)$00 roduct For"# late Filler Material M<4094% Trade Ea"e#
>ate# age#

$0)$0)0/ $ of 2

Choose Units For This Sheet

English Units


&rocess

SAW

&rocess

8as 9sed

N/A

8as 9sed

)mps Volts Wire +eed 7in:min.

$/ ' %$./ H / i!)"i!

)mps Volts Wire +eed 7in:min.

Metric Units

&rocess 2 2 i! 0.$2/ i! 0.$2/ i! 0.000 i! 0.$/0 i! 0.2/ i! Carbon Steel SAW-Twin Wire N/A

6D0 ' %2 H 2/0 i!)"i!

DETERMINING WELDING COST FOR A DOUBLE-V GROOVE WELD


?ase Material# 59<'46/)$00 roduct For"# late Filler Material M<4094% Trade Ea"e#
ro(ect# Co"pa!y# 5S!& 9ub(ect#

,eldi!g Cost

,eldi!g process1es C,F 9',

&lease choose 'nits before yo' enter data into the fields belo% &rocess , 2 i! Thic(ness 7in. 0.$2/ i! Cap ?eight FhF7in. 0.$2/ i! !oot ?eight FhF7in. 0.000 i! !oot Opening 7in. 0.$/0 i! !oot +ace7in. 0.2/ i! $epth of *eel 7$,. +iller material

>ate# age#

$0)$0)0/ $ of 2


English Units


Carbon Steel

&rocess

SAW

&rocess

8as 9sed

N/A

8as 9sed

)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. *eel )ngle Top Side *eel )ngle *ac( Total Weld Length 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr. Welder Efficiency Cost Electrode Cost of +l'= 7<:lb. Labor !ate 7<:hr. 8as Cost7per bottle. 8as Cylinder Sie 7ft;/. &o%er Cost

@!its G
Carbon Steel

N/A


)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. *eel )ngle Top Side *eel )ngle *ac( Total Weld Length 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr.

2.% ./ 60.00 4 0 0.20 $ $


Welder Efficiency Cost Electrode Cost of +l'= 7<:lb. Labor !ate 7<:hr. 8as Cost7per bottle. 8as Cylinder Sie 7ft;/. &o%er Cost


&rocess 2 2 i! 0.$2/ i! 0.$2/ i! 0.000 i! 0.$/0 i! 0.2/ i! SAW-Twin Wire

$/ %$./ / 0.$2/ // // /000 .00 0.00 50%

Metric Units

6D0 %2 2/0 0.062/ // // /000 20.00 0


40%

%.% ./ /0.00 4 0 0.$D


WELDING COST OUTPUT FOR A DOUBLE-V GROOVE WELD

O9T&9T +O! S)W '"ou!t of filler "etal !eeded '"ou!t of Flu; !eeded Eu"ber of passes per (oi!t K '"ou!t of shieldi!g gas used Eu"ber of :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate
J

H'<@-N lbs H'<@-N lbs H'<@-N H'<@-N ftI% E)' H'<@-N hr H'<@-N lb)hr H'<@-N H'<@-N H'<@-N 4 H'<@-N H'<@-N BV)L9E H'<@-N J)ft H'<@-N J)ft H'<@-N J)ft 4 J)ft H'<@-N J)ft H'<@-N lb welded i! D hr

O9T&9T +O! S)W"T%in Wire '"ou!t of filler "etal !eeded H'<@-N lbs '"ou!t of Flu; !eeded H'<@-N lbs


Flu; Cos t

:as Cos t

ower C os t

< ab or Co s t

,e ld i! g -l ectro de Co s t

:as Cos t

ower Cost

Fl u; C os t

WELDING COST OUTPUT FOR A DOUBLE-V GROOVE WELD

J

H'<@-N lbs H'<@-N lbs H'<@-N H'<@-N ftI% E)' H'<@-N hr H'<@-N lb)hr H'<@-N H'<@-N H'<@-N 4 H'<@-N H'<@-N BV)L9E H'<@-N J)ft H'<@-N J)ft H'<@-N J)ft 4 J)ft H'<@-N J)ft H'<@-N lb welded i! D hr

O9T&9T +O! S)W"T%in Wire '"ou!t of filler "etal !eeded H'<@-N lbs '"ou!t of Flu; !eeded H'<@-N lbs Eu"ber of passes per (oi!t K H'<@-N '"ou!t of shieldi!g gas used H'<@-N ftI% Eu"ber of :as ?ottles Be*uired E)' 'ctual weldi!g ti"e H'<@-N hr >epositio! Bate H'<@-N lb)hr
BV)L9E &roides a

BV)L9E


BBB


Flu; Cos t

:as Cos t

ower C os t

< ab or Co s t

,e ld i! g -l ectro de Co s t

:as Cos t

ower Cost

Fl u; C os t

BV)L9E &roides a

BV)L9E


BBB

DETERMINING WELDING COST FOR A SINGLE-U GROOVE WELD

Mark Mruczek ,eldi!g -!gi!eer Mruczek ,eldi!g -!gi!eeri!g

ro(ect# Co"pa!y# 9ub(ect#

,eldi!g Cost

,eldi!g process1es @sed#

?ase Material# 9'%%/ 422 roduct For"# ipe Filler Material -$T4$ Trade Ea"e#

>ate# age#

0D)0)02 $ of 2


English Units

Metric Units

Aoh!stow! '

&lease choose 'nits before yo' enter data into the fields belo% &rocess , 0.%/ i! Thic(ness 7in. 0.0$ i! Cap ?eight FhF7in. 0.$2/ i! !oot Opening 7in. 0.2/ i! !adi's of 9 grooe 0.062/ i! !adi's Offset 0.062/ i! !oot +ace7in. 0./ i! $epth of *eel 7$. +iller material &rocess 8as 9sed )mps Volts

Carbon Steel GTAW Ar

$%/ ' $D H

Thic(ness 7in. Cap ?eight FhF7in. !oot Opening 7in. !adi's of 9 grooe !adi's Offset !oot +ace7in. $epth of *eel 7$. +iller material

&rocess 2 2.D/ i! 0.$2/ i! 0.$2/ i! 0.2/ i! 0 i! 0.$2/ i! 2.D/ i! Carbon Steel

&rocess

FCAW (Gas)

8as 9sed

75Ar-25C02

)mps Volts

260 ' 26 H

DETERMINING WELDING COST FOR A SINGLE-U GROOVE WELD

Mark Mruczek ,eldi!g -!gi!eer Mruczek ,eldi!g -!gi!eeri!g

?ase Material# 9'%%/ 422 roduct For"# ipe Filler Material -$T4$ Trade Ea"e#


,eldi!g Cost


>ate# age#

0D)0)02 $ of 2


English Units

Metric Units

Aoh!stow! '

&lease choose 'nits before yo' enter data into the fields belo% &rocess , 0.%/ i! Thic(ness 7in. 0.0$ i! Cap ?eight FhF7in. 0.$2/ i! !oot Opening 7in. 0.2/ i! !adi's of 9 grooe 0.062/ i! !adi's Offset 0.062/ i! !oot +ace7in. 0./ i! $epth of *eel 7$. +iller material &rocess 8as 9sed )mps Volts Wire +eed 7in:min. Electrode $iam- 7in. *eel )ngle Top Side Total Weld Length 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr. Welder Efficiency Cost Electrode Cost of +l'= 7<:lb. Labor !ate 7<:hr. 8as Cost7per bottle. 8as Cylinder Sie 7ft;/. &o%er Cost


60%

$%/ $D 20 0.$2/ 20 .%2  %/ 07 .00 4 %$.00 /0.00 %%0 0.$D

@!its G
' H i!)"i! i! deg ft i!)"i! ftI%)hr J)lb J)lb J)hr J)bottle ftI% J)kwh

&rocess 2 2.D/ i! 0.$2/ i! 0.$2/ i! 0.2/ i! 0 i! 0.$2/ i! 2.D/ i!

Thic(ness 7in. Cap ?eight FhF7in. !oot Opening 7in. !adi's of 9 grooe !adi's Offset !oot +ace7in. $epth of *eel 7$. +iller material


Carbon Steel

&rocess

FCAW (Gas)

8as 9sed

75Ar-25C02

)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. *eel )ngle Top Side Total Weld Length 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr. Welder Efficiency Cost Electrode Cost of +l'= 7<:lb. Labor !ate 7<:hr. 8as Cost7per bottle. 8as Cylinder Sie 7ft;/. &o%er Cost

260 26 %$0 0.0/ $D $00 $D %/ 60% 07 6.00 4 %$.00 /0.00 %%0 0.$D

$ $


0

WELDING COST OUTPUT FOR A SINGLE-U GROOVE WELD

O9T&9T +O! 8T)W '"ou!t of filler "etal !eeded '"ou!t of Flu; !eeded Eu"ber of passes per (oi!t K '"ou!t of shieldi!g gas used Eu"ber of :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate
J

H'<@-N lbs 0.00 lbs H'<@-N H'<@-N ftI% H'<@-N H'<@-N hr H'<@-N lb)hr H'<@-N H'<@-N 4 H'<@-N H'<@-N H'<@-N BV)L9E H'<@-N J)ft H'<@-N J)ft 4 J)ft H'<@-N J)ft H'<@-N J)ft H'<@-N lb welded i! D hr

H'<@-N lbs 0.00 lbs

WELDING COST OUTPUT FOR A SINGLE-U GROOVE WELD

O9T&9T +O! 8T)W '"ou!t of filler "etal !eeded '"ou!t of Flu; !eeded Eu"ber of passes per (oi!t K '"ou!t of shieldi!g gas used Eu"ber of :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate
J

O9T&9T +O! +C)W 78as. '"ou!t of filler "etal !eeded '"ou!t of Flu; !eeded Eu"ber of passes per (oi!t K '"ou!t of shieldi!g gas used Eu"ber of :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate



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DETERMINING WELDING COST FOR A Double-U GROOVE WELD



,eldi!g Cost


&rocess ,

 Thic(ness 7in. 0.062/ Cap ?eight FhF7in. 0.$2/ !oot Opening 7in. 0./ !adi's of 9 Top Side 0./ !adi's of 9 *ottom Side 0 !adi's Offset Top Side 0 !adi's Offset *ottom 0.2/ !oot +ace7in. $.D/ $epth of *eel 7$. +iller material Carbon Steel &rocess MCAW 8as 9sed

&lease choose 'nits before yo' enter data into the fields belo% i! i! i! i! i! i! i! i! i!

98Ar-2Co2

)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. *eel )ngle Top Side

%2/ 2D 00 0.0/2 20

?ase Material# ' /$6 roduct For"# late Filler Material -$T4$ Trade Ea"e#

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0D)0)02 $ of 2 English Units

Thic(ness 7in. Cap ?eight FhF7in. !oot Opening 7in. !adi's of 9 grooe !adi's of 9 *ottom Side !adi's Offset Top Side !adi's Offset *ottom !oot +ace7in. $epth of *eel 7$. +iller material &rocess 8as 9sed )mps Volts Wire +eed 7in:min. Electrode $iam- 7in. *eel )ngle Top Side

Metric Units

&rocess 2  i! 0.062/ i! 0 i! 0./ i! 0./ i! 0.$% i! 0.$% i! 0.2/ i! $.D/ i! Carbon Steel GTAW N/A

%/0 2D 00 0.0/2 20

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DETERMINING WELDING COST FOR A Double-U GROOVE WELD


?ase Material# ' /$6 roduct For"# late Filler Material -$T4$ Trade Ea"e#


,eldi!g Cost


&rocess ,

 Thic(ness 7in. 0.062/ Cap ?eight FhF7in. 0.$2/ !oot Opening 7in. 0./ !adi's of 9 Top Side 0./ !adi's of 9 *ottom Side 0 !adi's Offset Top Side 0 !adi's Offset *ottom 0.2/ !oot +ace7in. $.D/ $epth of *eel 7$. +iller material Carbon Steel &rocess MCAW 8as 9sed

&lease choose 'nits before yo' enter data into the fields belo% i! i! i! i! i! i! i! i! i!

98Ar-2Co2

)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. *eel )ngle Top Side *eel )ngle *ac( Total Weld Length 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr. Welder Efficiency Cost Electrode Cost of +l'= 7<:lb. Labor !ate 7<:hr. 8as Cost7per bottle. 8as Cylinder Sie 7ft;/. &o%er Cost

%2/ 2D 00 0.0/2 20 20 $00 $0 %/


%.% 4 //.00 %/.00 %%0 0.$D



50%

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0D)0)02 $ of 2 English Units

Thic(ness 7in. Cap ?eight FhF7in. !oot Opening 7in. !adi's of 9 grooe !adi's of 9 *ottom Side !adi's Offset Top Side !adi's Offset *ottom !oot +ace7in. $epth of *eel 7$. +iller material &rocess 8as 9sed )mps Volts Wire +eed 7in:min. Electrode $iam- 7in. *eel )ngle Top Side *eel )ngle *ac( Total Weld Length 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr. Welder Efficiency Cost Electrode Cost of +l'= 7<:lb. Labor !ate 7<:hr. 8as Cost7per bottle. 8as Cylinder Sie 7ft;/. &o%er Cost

Metric Units

&rocess 2  i! 0.062/ i! 0 i! 0./ i! 0./ i! 0.$% i! 0.$% i! 0.2/ i! $.D/ i! Carbon Steel GTAW N/A

%/0 2D 00 0.0/2 20 20 $00 $0 %/


50%

%.% 4 //.00 %/.00 %%0 0.$D


$ $

WELDING COST OUTPUT FOR A DOUBLE-U GROOVE WELD

O9T&9T +O! C)W '"ou!t of filler "etal !eeded '"ou!t of Flu; !eeded Eu"ber of passes per (oi!t K '"ou!t of shieldi!g gas used Eu"ber of :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate
J

H'<@-N lbs 0.00 lbs H'<@-N passes H'<@-N ftI% H'<@-N bottle1s H'<@-N hr H'<@-N lb)hr H'<@-N H'<@-N 4 H'<@-N H'<@-N H'<@-N BV)L9E H'<@-N J)ft H'<@-N J)ft 4 J)ft H'<@-N J)ft H'<@-N J)ft H'<@-N lb welded i! D hr H'<@-N lbs 0.00 lbs

WELDING COST OUTPUT FOR A DOUBLE-U GROOVE WELD

O9T&9T +O! C)W '"ou!t of filler "etal !eeded '"ou!t of Flu; !eeded Eu"ber of passes per (oi!t K '"ou!t of shieldi!g gas used Eu"ber of :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate epositio! Bate

J

J

H'<@-N lbs 0.00 lbs H'<@-N passes H'<@-N ftI% H'<@-N bottle1s H'<@-N hr H'<@-N lb)hr H'<@-N H'<@-N 4 H'<@-N H'<@-N H'<@-N BV)L9E H'<@-N J)ft H'<@-N J)ft 4 J)ft H'<@-N J)ft H'<@-N J)ft H'<@-N lb welded i! D hr

,eldi!g -lectrode Cost Flu; Cost :as Cost ower Cost

H'<@-N lbs 0.00 lbs H'<@-N passes H'<@-N ftI% E)' bottle1s H'<@-N hr H'<@-N lb)hr H'<@-N H'<@-N 4 H'<@-N H'<@-N H'<@-N BV)L9E H'<@-N J)ft H'<@-N J)ft 4 J)ft H'<@-N J)ft H'<@-N J)ft H'<@-N lb welded i! D hr

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,eldi!g Cost a!d Ti"e

,eldi!g process1es @sed# :T',

?ase Material# 9'$06 roduct For"# ipe Filler Material -B0946 Trade Ea"e#


0/)$)0 $ of 2 English Units

Metric Units

Aoh!stow! '

&lease choose 'nits before yo' enter data into the fields belo% &rocess , 0./ i! Thic(ness 7in. 0.00$ i! Cap ?eight FhF7in. 0 i! !oot Opening 7in. 0.2/ i! !adi's of # grooe 0 i! !adi's Offset 0.$2/ i! !oot +ace7in. 0.2/ i! $epth of *eel 7$. +iller material &rocess 8as 9sed )mps Volts Wire +eed 7in:min.


$20 $/ 0 0.0%

' H i!)"i! i!

Thic(ness 7in. Cap ?eight FhF7in. !oot Opening 7in. !adi's of # grooe !adi's Offset !oot +ace7in. $epth of *eel 7$. +iller material &rocess 8as 9sed )mps Volts Wire +eed 7in:min.

&rocess 2 0./ i! 0.00$ i! 0 i! 0.2/ i! 0 i! 0.$2/ i! 0.2/ i! 0.$$2/ Carbon Steel 0.2/ GTAW Ar

$$/ $/ 0 0.0%

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DETERMINING WELDING COST FOR A SINGLE-J GROOVE WELD


&ro>ect3 Tube to 5eader ,elds Cost Company3 CM)-T S'b>ect3

,eldi!g Cost a!d Ti"e

,eldi!g process1es @sed# :T',

?ase Material# 9'$06 roduct For"# ipe Filler Material -B0946 Trade Ea"e#


0/)$)0 $ of 2 English Units

Metric Units

Aoh!stow! '

&lease choose 'nits before yo' enter data into the fields belo% &rocess , 0./ i! Thic(ness 7in. 0.00$ i! Cap ?eight FhF7in. 0 i! !oot Opening 7in. 0.2/ i! !adi's of # grooe 0 i! !adi's Offset 0.$2/ i! !oot +ace7in. 0.2/ i! $epth of *eel 7$. +iller material &rocess 8as 9sed

Carbon Steel


$20 $/ 0 0.0%/ 20 0.6/ % %/ 07 30% 2.62 4 /0.00 %0.00 %%0 0.20

GTAW Ar

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&rocess 2 0./ i! 0.00$ i! 0 i! 0.2/ i! 0 i! 0.$2/ i! 0.2/ i! 0.$$2/ Carbon Steel 0.2/ GTAW

Thic(ness 7in. Cap ?eight FhF7in. !oot Opening 7in. !adi's of # grooe !adi's Offset !oot +ace7in. $epth of *eel 7$. +iller material &rocess 8as 9sed


Ar


$$/ $/ 0 0.0%/ 20 0.6/  %/ % 30% 2.62 4 /0.00 %0.00 %%0 0.20


$ $

WELDING COST OUTPUT FOR A SINGLE-J GROOVE WELD

O9T&9T O9T&9T +O! 8T) 8T)W '"ou!t of filler "etal !eeded '"ou!t of Flu; !eeded Eu"ber of passes per (oi!t K '"ou!t of shieldi!g gas used Eu"ber of :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate
J

H'<@-N lbs 0.00 lbs H'<@-N passes H'<@-N ftI% 0 bottle1s H'<@-N hr H'<@-N lb lb)hr H'<@-N H'<@-N 4 H'<@-N H'<@-N H'<@-N BV)L9E H'<@-N J)ft H'<@-N J)ft 4 J)ft H'<@-N J) J ) ft H'<@-N J)ft H'<@-N lb l b welded i! D hr

H'<@-N lbs 0.00 lbs

WELDING COST OUTPUT FOR A SINGLE-J GROOVE WELD

O9T&9T O9T&9T +O! 8T) 8T)W '"ou!t of filler "etal !eeded '"ou!t of Flu; !eeded Eu"ber of passes per (oi!t K '"ou!t of shieldi!g gas used Eu"ber of :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate epositio! Bate

J

J

H'<@-N lbs 0.00 lbs H'<@-N passes H'<@-N ftI% 0 bottle1s H'<@-N hr H'<@-N lb lb)hr H'<@-N H'<@-N 4 H'<@-N H'<@-N H'<@-N BV)L9E H'<@-N J)ft H'<@-N J)ft 4 J)ft H'<@-N J) J ) ft H'<@-N J)ft H'<@-N lb l b welded i! D hr

H'<@-N lbs 0.00 lbs H'<@-N passes H'<@-N ftI% H'<@-N bottle1s H'<@-N hr H'<@-N lb lb)hr H'<@-N H'<@-N 4 H'<@-N H'<@-N H'<@-N BV)L9E H'<@-N J)ft H'<@-N J)ft 4 J)ft H'<@-N J) J ) ft H'<@-N J)ft H'<@-N lb l b welded i! D hr

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DETERMINING WELDING COST FOR A Double-J GROOVE WELD


ro(ect# M
,eldi!g Cost

,eldi!g process1es @sed# 9', ) 9',4T,

&lease choose 'nits before yo' enter data into the fields belo% &rocess ,  i! Thic(ness 7in. 0.06% i! Cap ?eight FhF7in. 0 i! !oot Opening 7in. 0./ i! !adi's of # grooe 0.$ i! !adi's Offset 0.2/ i! !oot +ace7in. $.D$2/ i! $epth of *eel 7$. +iller material &rocess 8as 9sed )mps Volts Wire +eed 7in:min. Electrode $iam- 7in.

Carbon Steel SAW N/A

/%/ %2 2D 0.062/

' H i!)"i! i!

?ase Material# 59<'4$00 roduct For"# late Filler Material -M9 Trade Ea"e#


0D)$)0/ $ of 2 English Units

Thic(ness 7in. Cap ?eight FhF7in. !oot Opening 7in. !adi's of # grooe !adi's Offset !oot +ace7in. $epth of *eel 7$. +iller material &rocess 8as 9sed )mps Volts Wire +eed 7in:min. Electrode $iam- 7in.

Metric Units

&rocess 2  i! 0.06 i! 0 i! 0./ i! 0.$ i! 0.%/ i! $.D$2/ i! Carbon Steel SAW N/A

2/ % %$/ 0.062/

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DETERMINING WELDING COST FOR A Double-J GROOVE WELD


ro(ect# M
,eldi!g Cost

,eldi!g process1es @sed# 9', ) 9',4T,

?ase Material# 59<'4$00 roduct For"# late Filler Material -M9 Trade Ea"e#

&lease choose 'nits before yo' enter data into the fields belo% &rocess ,  i! Thic(ness 7in. 0.06% i! Cap ?eight FhF7in. 0 i! !oot Opening 7in. 0./ i! !adi's of # grooe 0.$ i! !adi's Offset 0.2/ i! !oot +ace7in. $.D$2/ i! $epth of *eel 7$. +iller material &rocess 8as 9sed )mps Volts Wire +eed 7in:min. Electrode $iam- 7in. *eel )ngle Top Side *eel )ngle *ac( Side Total Weld Length 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr. Welder Efficiency Cost Electrode Cost of +l'= 7<:lb. Labor !ate 7<:hr. 8as Cost7per bottle. 8as Cylinder Sie 7ft;/. &o%er Cost

SAW N/A

50%

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' H i!)"i! i! deg deg ft i!)"i! ftI%)hr J)lb J)lb J)hr J)bottle ftI% J)kwh


0D)$)0/ $ of 2 English Units

Thic(ness 7in. Cap ?eight FhF7in. !oot Opening 7in. !adi's of # grooe !adi's Offset !oot +ace7in. $epth of *eel 7$. +iller material &rocess 8as 9sed

Carbon Steel

/%/ %2 2D 0.062/ %0 %0 $000 $2 0 07 %./ %./ /0.00 4 0 0.$D

>ate# age#


)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. *eel )ngle Top Side *eel )ngle *ac( Side Total Weld Length 7m. Trael Speed 7m:min. 8as +lo% !ate 7L:min. Welder Efficiency Cost Electrode Cost of +l'= 7<:lb. Labor !ate 7<:hr. 8as Cost7per bottle. 8as Cylinder Sie 7ft;/. &o%er Cost

Metric Units

&rocess 2  i! 0.06 i! 0 i! 0./ i! 0.$ i! 0.%/ i! $.D$2/ i! Carbon Steel SAW N/A

2/ % %$/ 0.062/ 2/ 2/ $000 $ 0 07 50% %.% %./ /0.00 4 0 0.$D

' H i!)"i! i! deg deg ft i!)"i! ftI%)hr J)lb J)lb J)hr J)bottle ftI% J)kwh

$ $

WELDING COST OUTPUT FOR A DOUBLE-J GROOVE WELD

J

H'<@-N lbs H'<@-N lbs H'<@-N passes H'<@-N ftI% E)' bottle1s H'<@-N hr H'<@-N lb)hr H'<@-N H'<@-N H'<@-N 4 H'<@-N H'<@-N BV)L9E H'<@-N J)ft H'<@-N J)ft H'<@-N J)ft 4 J)ft H'<@-N J)ft H'<@-N lb welded i! D hr

H'<@-N lbs H'<@-N lbs

WELDING COST OUTPUT FOR A DOUBLE-J GROOVE WELD

O9T&9T +O! S)W '"ou!t of filler "etal !eeded '"ou!t of Flu; !eeded Eu"ber of passes per (oi!t K '"ou!t of shieldi!g gas used Eu"ber of :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate epositio! Bate

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DETERMINING WELDING COST FOR WELD OVERLAY/SURFACING

&ro>ect3 Goma G'lshan *'c(et Oerlay Company3 5)ES &o%er Contractors


S'b>ect3 Welding Cost A Time Welding process7es. 9sed3 +C)W

&lease choose 'nits before yo' enter data into the fields belo% &rocess , Width"W 7in. /6./ i! 0.2/ i! Oerlay thic(ness 7S. +iller material Stainless Steel &rocess

FCAW (Gas)0

8as 9sed

75Ar-25C02

$0 26 %2/ 0.0/2 $00 $0.0 %/

)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. Total Length of Weld 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr. Welder Efficiency Cost Electrode 7<:lb.

*ase aterial3 99 &rod'ct +orm3 +iller aterial -$0EiMo Metrode Trade 5ame3

$ate3 &age3

$$)%0)06 $ of 2


English Units

Leg Sie 7in. Oerlay thic(ness 7S. +iller material &rocess 8as 9sed


40%

6.00 J)lb

)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. Total Length of Weld 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr. Welder Efficiency Cost Electrode 7<:lb.

Metric Unit

&rocess 2 /6./ i! 0.2/ i! Stainless Steel

0 GMAW (Spray) 75Ar-25C02

$2/ 22 200 0.$/6 $00 /.0 %/


30%

%.00 J)lb

DETERMINING WELDING COST FOR WELD OVERLAY/SURFACING

&ro>ect3 Goma G'lshan *'c(et Oerlay Company3 5)ES &o%er Contractors


S'b>ect3 Welding Cost A Time Welding process7es. 9sed3 +C)W

*ase aterial3 99 &rod'ct +orm3 +iller aterial -$0EiMo Metrode Trade 5ame3

&lease choose 'nits before yo' enter data into the fields belo% &rocess , Width"W 7in. /6./ i! 0.2/ i! Oerlay thic(ness 7S. +iller material Stainless Steel &rocess

FCAW (Gas)0

8as 9sed

75Ar-25C02

)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. Total Length of Weld 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr. Welder Efficiency Cost Electrode 7<:lb. Labor:Oerhead !ate Cost of 8as 8as Cylinder Sie 7ft;/. &o%er Cost Cost of +l'= 7<:lb.

$ate3 &age3

$$)%0)06 $ of 2


English Units

Leg Sie 7in. Oerlay thic(ness 7S. +iller material &rocess 8as 9sed

$0 26 %2/ 0.0/2 $00 $0.0 %/


6.00 60.00 0.00 %%0.00 0.20 4


)mps Volts Wire +eed 7in:min. Electrode $iam- 7in. Total Length of Weld 7ft. Trael Speed 7in:min. 8as +lo% !ate 7ft;/:hr. Welder Efficiency Cost Electrode 7<:lb. Labor:Oerhead !ate Cost of 8as 8as Cylinder Sie 7ft;/. &o%er Cost

40%

Cost of +l'= 7<:lb.

Metric Unit

&rocess 2 /6./ i! 0.2/ i! Stainless Steel

0 GMAW (Spray) 75Ar-25C02

$2/ 22 200 0.$/6 $00 /.0 %/


30%

%.00 60.00 %0.00 %%0.00 0.20 4



@!its G
$ $ WELDING COST OUTPUT FOR A FILLET WELD

O9T&9T +O! +C)W 78as. '"ou!t of filler "etal !eeded

/60/.06 lbs

'"ou!t of shieldi!g gas used Eu"ber of :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate
H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N J %%6%0.%/ H'<@-N J 4 H'<@-N H'<@-N BV)L9E H'<@-N %%6.%0 4 H'<@-N H'<@-N

O9T&9T +O! 8)W 7Spray. '"ou!t of filler "etal !eeded

ftI%

Flu; Cost 6ow er Cost

hr lb)hr ,eldi!g -lectrode Cost $007

J)ft J)ft J)ft J)ft J)ft

/0%%.$$ lbs

O9T&9T +O! +C)W 78as. '"ou!t of filler "etal !eeded

/60/.06 lbs

'"ou!t of shieldi!g gas used Eu"ber of :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate
H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N J %%6%0.%/ H'<@-N J 4 H'<@-N H'<@-N BV)L9E H'<@-N %%6.%0 4 H'<@-N H'<@-N

O9T&9T +O! 8)W 7Spray. '"ou!t of filler "etal !eeded

ftI%

Flu; Cost 6ow er Cost

hr lb)hr ,eldi!g -lectrode Cost $007


/0%%.$$ lbs

,eldi!g -lectrode Cost :as Cost

'"ou!t of shieldi!g gas Eu"ber of :as ?ottles Be*uired 'ctual weldi!g ti"e >epositio! Bate

H'<@-N H'<@-N H'<@-N H'<@-N H'<@-N J $6D$/.20 H'<@-N J 4 H'<@-N H'<@-N BV)L9E H'<@-N $6D.$/ 4 H'<@-N H'<@-N

BV)L9E

Flu; Cost

ftI%

6ow er Cost

hr lb)hr



,eldi!g -lectrode Cost $007


BV)L9E


Weld Cost CalcHL

,ritte! ?y# 'ark (. 'ruc)ek Copyright © *++, 'ark (. 'ruc)ek

9pdates since inception

>ate Cha!ge $64May402 Added -pdate Sheet Check Spelling Checked Against Sa#ple Calculations /4Feb40% Added Co#pound Single evel /oint to the spreadsheet 'oved all calculations to a separate page D4Aul40% Added $ouble012 and $ouble evel joint to the spreadsheet

Weld Cost CalcHL

,ritte! ?y# 'ark (. 'ruc)ek Copyright © *++, 'ark (. 'ruc)ek

9pdates since inception

>ate Cha!ge $64May402 Added -pdate Sheet Check Spelling Checked Against Sa#ple Calculations /4Feb40% Added Co#pound Single evel /oint to the spreadsheet 'oved all calculations to a separate page D4Aul40% Added $ouble012 and $ouble evel joint to the spreadsheet Sa#ple 1alues Entered $04=ct40% Added -nits page Added units conversion 1 code to each sheet $4Aa!40 Added Single0-2 Single0/2 and $ouble0/ /oints to the spreadsheet -pdated all weld joint drawing using Arc Works drawing software (ro# the Lincoln Electric co#p -pdated %ables page to add #ore base #etals2 gases and welder efficiencies 24'pr40 Corrected errors in cost calculations 3rotected Spreadsheet 4'ug40/ Added $eposition rate page to the spreadsheet Corrected errors in unit conversion calculations in 1 code -pdated Weld /oint $rawings Sa#ple Calcs &an01erification Co#plete Added 4otes to (illet weld page and fillet weld drawing showing flat and conve5 beads $2))$)200/ Changed 4a#e fro# Weld Cost &ev 6 to Weld Cost Calc7L %04Aa!406 (iled for Copyright 2$4Eov406 -pgraded progra# to correct deposition rate calculation. Added overlay cost worksheet for weld 24Eov406 Added the ability to have user input SAW flu5 consu#ption ratio in lieu of assu#ing 8 9 lb of flu for every lb of welding wire: $/4'pr40 Corrected calculation proble# with fillet weld sheet

Weld Cost Calc XL

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