DETERMINING WELDING COST FOR A FILLET WELD

Mark Mruczek Project: Base Material: A 516 Date: 08/07/02

Welding Engineer Company: Product Form: Plate Page: 1 of 2
Subject: Welding Cost Filler Material
Welding process Used: Trade Name:

Process 1 Process 2
Leg Size (in) 0.250 Leg Size (in) 0.250
Filler material Carbon Steel Filler material Carbon Steel

Process SMAW (14" Stick) Process FCAW (Gas)

Gas Used N/A Gas Used Co2
Amps 200 Amps 200
Volts 21 Volts 21
Wire Feed (in/min) 0 Wire Feed (in/min) 190
Wire Diam. (in) 0.187 Wire Diam. (in) 0.045
Total Length of Weld(ft) 10 Total Length of Weld(ft) 10
Travel Speed (ipm) 6 Travel Speed (ipm) 8
Gas Flow Rate (cfh) 0 Gas Flow Rate (cfh) 40
Welder Efficiency 30% Welder Efficiency 50%
Cost Electrode($/lb) 1.3 Cost Electrode($/lb) 2.5
Labor Rate ($/hr) 60 Labor Rate ($/hr) 60
Cost of Gas (per bottle) $0.00 Cost of Gas (per bottle) $70.00
Weight of gas (1 bottle) (lb) 0 Weight of gas (1 bottle) (lb) 50
Power Cost ($/kilowatt-hr) $0.15 Power Cost ($/kilowatt-hr) $0.15
 WELDING COST OUTPUT FOR A FILLET WELD
OUTPUT FOR PROCESS 1 SMAW (14" Stick)
Amount of weld wire needed 2.00 lb
Number of passes per joint ~ 1
Size of fillet weld** 0.290 in
Amount of shielding gas 0.00 ft^3 bottles = N/A
Labor Cost
Actual welding time 1.80 hr
Labor Cost Welding Wire Cost
Labor Cost $108.15 97% Gas Cost
Welding Wire Cost $2.60 Power Cost
Gas Cost $0.00
Power Cost $0.35
Welding Wire Cost
Initial Cost $111.10
2%
Final Cost $127.80
Power Cost
0%

Cost per ft of weld $11.11 $/ft

Cost per foot filler metal $0.26 $/ft
Cost per foot of gas $0.00 $/ft
Cost of Labor per foot $10.82 $/ft
** Size of the fillet weld is based on heat input. This information can be used to adjust your amps & volts to achieve the leg size you entered in B10
OUTPUT FOR PROCESS 2 FCAW (Gas)
Amount of weld wire needed 2.00 lb
Number of passes per joint ~ 1
Size of fillet weld** 0.251 in
Amount of shielding gas 0.00 ft^3 bottles = 1
Actual welding time 0.78 hr Labor Cost
Welding Wire Cost
Labor Cost $46.80 Labor Cost
Welding Wire Cost $5.00 86% Gas Cost
Gas Cost $2.55 Power Cost
Power Cost $0.25
Welding Wire Cost
Initial Cost $54.60 9%
Final Cost $62.80
Gas Cost
5%
Power Cost
Cost per ft of weld $5.46 $/ft 0%
Cost per foot filler metal $0.50 $/ft
Cost per foot of gas $0.26 $/ft
 5%
Power Cost
0%

Cost of Labor per foot $4.68 $/ft

Carbon Steel

FCAW (Gas)
 Labor Cost

Labor Cost Welding Wire Cost

97% Gas Cost
Power Cost

Welding Wire Cost

2%
Power Cost
0%
 DETERMINING WELDING COST FOR A SINGLE-V GROOVE WELD

Mark Mruczek Project: Base Material: A 516 Date: 08/07/02

Welding Engineer Company: Product Form: Plate Page: 1 of 2
Subject: Welding Cost Filler Material E7018
Welding process Used: Trade Name:

Process 1 Process 2
Thickness (in) 0.438 Thickness (in) 0.625
Height of "h" (in) 0.125 Height of "h" (in) 0.063
Root Opening (in) 0.125 Root Opening (in) 0.094
Root Face(in) 0.063 Root Face(in) 0.063

Filler material Carbon Steel Filler material Carbon Steel

Process SMAW (12" Stick) Process FCAW (Gas)

Gas Used N/A Gas Used C25
Amps 130 Amps
Volts 27 Volts
Wire Feed (in/min) 0 Wire Feed (in/min)
Wire Diam. (in) 0.1576 Wire Diam. (in)
Joint Angle 70 Joint Angle
Total Length of Weld(ft) 8.9 Total Length of Weld(ft)
Travel Speed (ipm) 6 Travel Speed (ipm)
Gas Flow Rate (cfh) 0 Gas Flow Rate (cfh)
Welder Efficiency 30% Welder Efficiency
Cost Electrode($/lb) 1.26 Cost Electrode($/lb)
Labor Rate ($/hr) 60 Labor Rate ($/hr)
Cost of Gas (per bottle) $0.00 Cost of Gas (per bottle)
Weight of gas in one bottle ( 0 Weight of gas in one bottle (l
Power Cost ($/kilowatt-hr) $0.10 Power Cost ($/kilowatt-hr)
 WELDING COST OUTPUT FOR A SINGLE-V GROOVE WELD

OUTPUT FOR SMAW (12" Stick)

Amount of weld wire needed 10.70 lb
Number of passes per joint ~ 6 Labor Cost
Amount of shielding gas 0.00 ft^3 bottles = N/A Welding Wire Cost
Actual welding time 16.83 hr Gas Cost
Power Cost
Labor Cost $595.66 Labor Cost
Welding Wire Cost $13.48 98%
Gas Cost $0.00
Power Cost $1.77
Initial Cost $610.91
Final Cost $702.55
Welding Wire Cost
2%
Power Cost
Cost per ft of weld $68.64 $/ft 0%
Cost per foot filler metal $1.52 $/ft
Cost per foot of gas $0.00 $/ft
Cost of Labor per foot $66.93 $/ft

OUTPUT FOR FCAW (Gas)

Amount of weld wire needed 1197.52 lb
Number of passes per joint ~ 10
Amount of shielding gas 6897.88 ft^3 bottles = 16
Actual welding time 394.16 hr

Labor Cost $20,338.90

Welding Wire Cost $2,694.42 Labor Cost
Gas Cost $1,189.88 Gas Cost Welding Wire Cost
5%
Power Cost $94.60 Welding Wire Cost Gas Cost
Power Cost
Initial Cost $24,317.80 11%
0% Power Cost
Final Cost $ 27,965.47

Cost per ft of weld $24.32 $/ft Labor Cost

84%
Cost per foot filler metal $2.69 $/ft
Cost per foot of gas $1.19 $/ft
Cost of Labor per foot $20.34 $/ft
Labor Cost
84%
Process 2

Carbon Steel

FCAW (Gas)
C25
200
20
225
0.05
60
1000
8
35
50%
2.25
60
$75.00
50
$0.12
 Labor Cost
Welding Wire Cost
Gas Cost
Power Cost

Labor Cost
98%

Welding Wire Cost

2%
Power Cost
0%

Labor Cost
Gas Cost Welding Wire Cost
5%
Welding Wire Cost
Power Cost
Gas Cost
11%
0% Power Cost

Labor Cost
84%
Labor Cost
84%
 DETERMINING WELDING COST FOR A SINGLE-BEVEL GROOVE WELD

Mark Mruczek Project: Base Material: A 516 Date: 05/22/02

Welding Engineer Company: Product Form: Plate Page: 1 of 2
Subject: Welding Cost Filler Material E7018
Welding process Used: SMAW + GMAW Trade Name: Lincoln

Process 1 Process 2
Thickness (in) 2.25 Thickness (in) 2.25
Height of "h" (in) 0.09375 Height of "h" (in) 0.09375
Root Opening (in) 0.125 Root Opening (in) 0.125
Root Face(in) 0.09375 Root Face(in) 0.09375

Filler material Carbon Steel Filler material Carbon Steel

Process FCAW (Gas) Process SMAW (14" Stick)

Gas Used C25 Gas Used N/A
Amps 200 Amps
Volts 21 Volts
Wire Feed (in/min) 225 Wire Feed (in/min)
Wire Diam. (in) 0.052 Wire Diam. (in)
Joint Angle 45 Joint Angle
Total Length of Weld(ft) 3.535 Total Length of Weld(ft)
Travel Speed (ipm) 9 Travel Speed (ipm)
Gas Flow Rate (cfh) 35 Gas Flow Rate (cfh)
Welder Efficiency 50% Welder Efficiency
Cost Electrode($/lb) 2.45 Cost Electrode($/lb)
Labor Rate ($/hr) 50 Labor Rate ($/hr)
Cost of Gas (per bottle) $50.00 Cost of Gas (per bottle)
Weight of gas in one bottle 50 Weight of gas in one bottle (l
Power Cost ($/kilowatt-hr) $0.15 Power Cost ($/kilowatt-hr)
 WELDING COST OUTPUT FOR A SINGLE-BEVEL GROOVE WELD

OUTPUT FOR FCAW (Gas)

Amount of weld wire needed 38.37 lb
Number of passes per joint ~ 100
Amount of shielding gas 165.52 ft^3 bottles = 1
Actual welding time 9.46 hr

Labor Cost $406.70 Labor Cost

Welding Wire Cost $94.01 Gas Cost Power Cost
78% Labor Cost
4% 1%
Gas Cost $19.03 Welding Wire Cost
Welding Wire Cost
Power Cost $2.98 18% Gas Cost
Initial Cost $522.72 Power Cost
Final Cost $ 601.13

Cost per ft of weld $147.87 $/ft

Cost per foot filler metal $26.59 $/ft
Cost per foot of gas $5.38 $/ft
Cost of Labor per foot $115.05 $/ft

OUTPUT FOR SMAW (14" Stick)

Amount of weld wire needed 54.00 lb
Number of passes per joint ~ 73
Amount of shielding gas 0.00 ft^3 bottles = N/A
Actual welding time 60.00 hr

Labor Cost $3,000.00 Labor Cost

Welding Wire Cost $70.20 98% Labor Cost
Gas Cost $0.00 Welding Wire Cost
Power Cost $0.28 Gas Cost
Welding Wire Cost
Initial Cost $3,081.00 2%
Power Cost
Final Cost $ 3,543.15
Power Cost
0%

Cost per ft of weld $871.57 $/ft

Cost per foot filler metal $19.86 $/ft
Cost per foot of gas $0.00 $/ft
 0%

Cost of Labor per foot $848.66 $/ft

Process 2

Carbon Steel

SMAW (14" Stick)

N/A
175
20
0
0.188
45
3.535
5.5
0
30%
1.3
50
$0.00
0
$0.15
 Labor Cost
Gas Cost Power Cost
78% Labor Cost
4% 1%
Welding Wire Cost
Welding Wire Cost
18% Gas Cost
Power Cost

Labor Cost
98% Labor Cost
Welding Wire Cost
Gas Cost
Welding Wire Cost
Power Cost
2%
Power Cost
0%
0%
 CALCULATIONS PROCESS 1 Single-V Groove
distance "d" = 0.375 in Process Efficiency 59% Process SMAW (12" Stick)
Distance "R" = 0.4578 in Welder Efficiency 30% Bottles of gas needed N/A
Distance c1 = 0.5252 in Arc Time 5.05 hr Radius of cap "r" 0.485202
Distance "c" = 0.6502 in Total welding time 16.83 hr Deposited Weld Metal Wt. 6
Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0 lb/ft^3
Area Cap "C" 0.0557 in^2 Volume of gas in one 0.00 ft^3
Weld Metal Weight "C" 0.1893 lb/ft bottle
Area Rectangle "A" 0.0547 in^2 Total gas needed 0.00 ft^3
Weld Metal Weight "A" 0.186 lb/ft Labor Cost $ 595.66
Area of two Triangles "B" 0.0985 in^2 Gas Cost $0.00
Weld Metal Weight "B" 0.334 lb/ft Cost Electrode $13.48
Total Weld Metal Weight 0.7094 lb/ft Total Cost $ 610.91
Amount of Welding Wire 10.70 lb Final Cost $ 91.64 $ 702.55
Deposition Rate 2.12 Lb/hr Heat Input 35
Total Power Cost $1.77 Number of Passes 6

CALCULATIONS PROCESS 2 Single-V Groove

distance "d" = 0.5625 in Process Efficiency 86% Process FCAW (Gas)
Distance "R" = 0.6495 in Welder Efficiency 50% Bottles of gas needed 16
Distance c1 = 0.7451 in Arc Time 197.08 hr Radius of cap "r" 1.438578
Distance "c" = 0.8388 in Total welding time 394.16 hr Deposited Weld Metal Wt. 1029.867
Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0.115 lb/ft^3
Area Cap "C" 0.0351 in^2 Volume of gas in one 434.78 ft^3
Weld Metal Weight "C" 0.1192 lb/ft bottle
Area Rectangle "A" 0.0586 in^2 Total gas needed 6897.88 ft^3
Weld Metal Weight "A" 0.199 lb/ft Labor Cost $ 20,338.90
Area of two Triangles "B" 0.2096 in^2 Gas Cost $1,189.88
Weld Metal Weight "B" 0.712 lb/ft Cost Electrode $2,694.42
Total Weld Metal Weight 1.0299 lb/ft Total Cost $ 24,317.80
Amount of Welding Wire 1197.52 lb Final Cost $ 3,647.67 $ 27,965.47
Deposition Rate 6.08 Lb/hr Heat Input 30
Total Power Cost $94.60 Number of Passes 10
 CALCULATIONS PROCESS 1 Single-Bevel Groove
distance "d" = 2.15625 in Process Efficiency 86% Process FCAW (Gas)
Distance "R" = 3.0494 in Welder Efficiency 50% Bottles of gas needed 1
Distance c1 = 2.1563 in Arc Time 4.73 hr Radius of cap "r" 6.986
Distance "c" = 2.2813 in Total welding time 9.46 hr Beta 45
Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0.115 lb/ft^3 Deposited Weld Metal Wt. 33.00
Area Cap "C" 0.1428 in^2 Volume of gas in one 434.78 ft^3
Weld Metal Weight "C" 0.4848 lb/ft bottle
Area Rectangle "A" 0.2813 in^2 Total gas needed 165.52 ft^3
Weld Metal Weight "A" 0.955 lb/ft Labor Cost $ 406.70
Area of two Triangles "B" 2.3247 in^2 Gas Cost $19.03
Weld Metal Weight "B" 7.895 lb/ft Cost Electrode $94.01
Total Weld Metal Weight 9.335 lb/ft Total Cost $ 522.72
Amount of Welding Wire 38.37 lb Final Cost $ 78.41 $ 601.13
Deposition Rate 8.11 Lb/hr Heat Input 28
Total Power Cost $2.98 Number of Passes 100

CALCULATIONS PROCESS 2 Single-Bevel Groove

distance "d" = 2.15625 in Process Efficiency 62% Process SMAW (14" Stick)
Distance "R" = 3.0494 in Welder Efficiency 30% Bottles of gas needed N/A
Distance c1 = 2.1563 in Arc Time 18.00 hr Radius of cap "r" 6.986
Distance "c" = 2.2813 in Total welding time 60.00 hr Beta 45
Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0 lb/ft^3 Deposited Weld Metal Wt. 33.00
Area Cap "C" 0.1428 in^2 Volume of gas in one 0.00 ft^3
Weld Metal Weight "C" 0.4848 lb/ft bottle
Area Rectangle "A" 0.2813 in^2 Total gas needed 0.00 ft^3
Weld Metal Weight "A" 0.955 lb/ft Labor Cost $ 3,000.00
Area of two Triangles "B" 2.3247 in^2 Gas Cost $0.00
Weld Metal Weight "B" 7.895 lb/ft Cost Electrode $70.20
Total Weld Metal Weight 9.335 lb/ft Total Cost $ 3,081.00
Amount of Welding Wire 54.00 lb Final Cost $ 3,543.15
Deposition Rate 3.000 Lb/hr Heat Input 38.18181818
Total Power Cost $10.80 Number of Passes 73

CALCULATIONS PROCESS 1 Fillet Weld

Area of Fillet Weld 0.0313 in2 Process Efficiency 62%
Volume of Weld Metal 3.750 in3 Welder Efficiency 30%
Filler Density lb/in3 0.283 lb/in3 Arc Time 0.541 hr
Total Weld Metal Weight 0.106 lb/ft Total welding time 1.802 hr
Amount of Welding Wire 2.000 lb Heat Input 42 kJ/in
Deposition Rate 3.700 lb/hr Fillet Weld Size 0.290 in
Density of gas 0 lb/ft3 Number of Passes 1
Volume of gas in one 0 ft3 Labor Cost $108.15
bottle Gas Cost $0.00
Total gas needed 0 ft3 Cost Electrode $2.60
Bottles of gas needed N/A Total Power Cost $0.35
Process SMAW (14" Stick) Total Cost $111.10
Final Cost $127.80

CALCULATIONS PROCESS 2 Fillet Weld

Area of Fillet Weld 0.0313 in2 Process Efficiency 86%
Volume of Weld Metal 3.750 in 3
Welder Efficiency 50%
Filler Density lb/in3 0.283 lb/in3 Arc Time 0.390 hr
Total Weld Metal Weight 0.106 lb/ft Total welding time 0.780 hr
Amount of Welding Wire 2.000 lb Heat Input 31.5 kJ/in
Deposition Rate 5.1310494 lb/hr Fillet Weld Size 0.251 in
Density of gas 0.116 lb/ft3 Number of Passes 1
Volume of gas in one 431.034483 ft 3
Labor Cost $46.80
bottle Gas Cost $2.55
Total gas needed 15.5913525 ft 3
Cost Electrode $5.00
Bottles of gas needed 1 Total Power Cost $0.25
Process FCAW (Gas) Total Cost $54.60
Final Cost $62.80
SMAW (12" Stick)

in
lb

FCAW (Gas)

in
lb
FCAW (Gas)

in

lb

SMAW (14" Stick)

in

lb
 Alloy Density Process&Welder Eff (%) GAS Densities Cap Hieght
Carbon Steel 0.283 SAW 99% 70% N/A 0 0
Stainless Steel 0.29 GMAW (98Ar-2O2) 98% 50% Ar 0.111 0.03125
Nickel Alloy 0.31 GMAW (75Ar-25CO2) 96% 50% Co2 0.116 0.063
GMAW CO2 93% 50% C25 0.115 0.094
1 1 FCAW (Gas) 86% 50% 1 4 Single V 0.125
1 1 FCAW (Self Shield) 78% 50% 4 1 Single Bev 0.25
1 1 SMAW (12" Stick) 59% 30% 1 3 Fillet 0.375
SMAW (14" Stick) 0.62 30% 4
SMAW (18" Stick) 66% 30% 3
7 5 Sing-V 3
5 8 Sing-Bev 3
8 5 Fillet 4
Interpolation of Deposit Single_V Interpolation of Deposit 3
Rate Process 1 5 Deposition Rates SMAW 7 Rate Process 1
0.000 0 110 1.8 0 0.000
0.000 0 125 2 125 2.120
0.000 0 150 2.6 0 0.000
0.000 0 175 3 0 0.000
6.076 200 200 3.7 0 0.000
0.000 0 225 4.2 0 0.000
0.000 0 275 7 0 0.000
0.000 0 325 9 0 0.000
6.076 400 10 2.120

Weld Size
0.125 Interpolation of Deposit Single Bevel Interpolation of Deposit
0.1875 Rate Process 1 8 Deposition Rates SMAW 5 Rate Process 1
0.250 0.000 0 110 1.8 0 0.000
0.313 0.000 0 125 2 0 0.000
0.375 0.000 0 150 2.6 0 0.000
0.438 3.000 175 175 3 0 0.000
0.500 0.000 0 200 3.7 200 8.114
0.5625 0.000 0 225 4.2 0 0.000
0.625 0.000 0 275 7 0 0.000
0.688 0.000 0 325 9 0 0.000
0.750 3.000 400 10 8.114
0.8125
0.875 Interpolation of Deposit Fillet Weld Interpolation of Deposit
 0.938 Rate Process 1 8 Deposition Rates SMAW 5 Rate Process 1
1.000 0.000 0 110 1.8 0 0
1.125 0.000 0 125 2 0 0
1.25 0.000 0 150 2.6 0 0
1.375 0.00 0 175 3 0 0
1.5 3.700 200 200 3.7 200 5.131
1.5625 0.000 0 225 4.2 0 0
1.625 0.000 0 275 7 0 0
1.75 0.000 0 325 9 0 0
1.8125 3.700 400 10 5.131
1.875
2
2.125
2.25
2.375
2.5
2.5625
2.625
2.75
2.8125
2.875
3
3.125
3.25
3.375
3.5
3.5625
3.625
3.75
3.8125
Single V 6 9
Single Bevel 27 27
Fillet Weld 3 3
4
2
2
3
4
3