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 Filler material
Process Process
Gas Used Gas Used
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
Actual welding time 1.80 hr
Labor Cost $108.15
Welding Wire Cost $2.60
Gas Cost $0.00
Power Cost $0.35
Initial Cost $111.10
Final Cost $127.80
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 $46.80
Welding Wire Cost $5.00
Gas Cost $2.55
Power Cost $0.25
Initial Cost $54.60
Final Cost $62.80
Cost per ft of weld $5.46 $/ft
Cost per foot filler metal $0.50 $/ft
Cost per foot of gas $0.26 $/ft
Cost of Labor per foot $4.68 $/ft
Labor Cost
98%
Welding Wire Cost
2%
Gas Cost
0%
Power Cost
0%
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
Labor Cost
86%
Welding Wire
Cost
9%
Gas Cost
5%
Power Cost
0%
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
DETERMINING WELDING COST FOR A SINGLE-V GROOVE WELD
Mark Mruczek Project: Base Material: A 516 Date: 08/07/02
Welding Engineer Company: Product Form: Plate Page: 1 of 2
Subject: Welding Cost Filler Material E7018
Welding process Used: Trade Name:
Process 1 Process 2
Thickness (in) 0.438 Thickness (in) 0.625
Height of "h" (in) 0.125 Height of "h" (in) 0.063
Root Opening (in) 0.125 Root Opening (in) 0.094
Root Face(in) 0.063 Root Face(in) 0.063
Filler material Filler material
Process Process
Gas Used Gas Used
Amps 130 Amps
Volts 27 Volts
Wire Feed (in/min) 0 Wire Feed (in/min)
Wire Diam. (in) 0.1576 Wire Diam. (in)
Joint Angle 70 Joint Angle
Total Length of Weld(ft) 8.9 Total Length of Weld(ft)
Travel Speed (ipm) 6 Travel Speed (ipm)
Gas Flow Rate (cfh) 0 Gas Flow Rate (cfh)
Welder Efficiency 30% Welder Efficiency
Cost Electrode($/lb) 1.26 Cost Electrode($/lb)
Labor Rate ($/hr) 60 Labor Rate ($/hr)
Cost of Gas (per bottle) $0.00 Cost of Gas (per bottle)
Weight of gas in one bottle (lb) 0 Weight of gas in one bottle (lb)
Power Cost ($/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
Amount of shielding gas 0.00 ft^3 bottles = N/A
Actual welding time 16.83 hr
Labor Cost $595.66
Welding Wire Cost $13.48
Gas Cost $0.00
Power Cost $1.77
Initial Cost $610.91
Final Cost $702.55
Cost per ft of weld $68.64 $/ft
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
Gas Cost $1,189.88
Power Cost $94.60
Initial Cost $24,317.80
Final Cost 27,965.47 $
Cost per ft of weld $24.32 $/ft
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%
Welding Wire Cost
11%
Gas Cost
5%
Power Cost
0%
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
Labor Cost
98%
Welding Wire Cost
2%
Gas Cost
0%
Power Cost
0%
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
Process 2
200
20
225
0.05
60
1000
8
35
50%
2.25
60
$75.00
50
$0.12
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
Welding Wire Cost
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
DETERMINING WELDING COST FOR A SINGLE-BEVEL GROOVE WELD
Mark Mruczek Project: Base Material: A 516 Date: 05/22/02
Welding Engineer Company: Product Form: Plate Page: 1 of 2
Subject: Welding Cost Filler Material E7018
Welding process Used: SMAW + GMAW Trade Name: Lincoln
Process 1 Process 2
Thickness (in) 2.25 Thickness (in) 2.25
Height of "h" (in) 0.09375 Height of "h" (in) 0.09375
Root Opening (in) 0.125 Root Opening (in) 0.125
Root Face(in) 0.09375 Root Face(in) 0.09375
Filler material Filler material
Process Process
Gas Used Gas Used
Amps 200 Amps
Volts 21 Volts
Wire Feed (in/min) 225 Wire Feed (in/min)
Wire Diam. (in) 0.052 Wire Diam. (in)
Joint Angle 45 Joint Angle
Total Length of Weld(ft) 3.535 Total Length of Weld(ft)
Travel Speed (ipm) 9 Travel Speed (ipm)
Gas Flow Rate (cfh) 35 Gas Flow Rate (cfh)
Welder Efficiency 50% Welder Efficiency
Cost Electrode($/lb) 2.45 Cost Electrode($/lb)
Labor Rate ($/hr) 50 Labor Rate ($/hr)
Cost of Gas (per bottle) $50.00 Cost of Gas (per bottle)
Weight of gas in one bottle 50 Weight of gas in one bottle (lb)
Power Cost ($/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
Welding Wire Cost $94.01
Gas Cost $19.03
Power Cost $2.98
Initial Cost $522.72
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
Welding Wire Cost $70.20
Gas Cost $0.00
Power Cost $0.28
Initial Cost $3,081.00
Final Cost 3,543.15 $
Cost per ft of weld $871.57 $/ft
Cost per foot filler metal $19.86 $/ft
Cost per foot of gas $0.00 $/ft
Cost of Labor per foot $848.66 $/ft
Labor Cost
78%
Welding Wire Cost
18%
Gas Cost
4% Power Cost
0%
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
Labor Cost
98%
Welding Wire
Cost
2%
Gas Cost
0%
Power Cost
0%
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
Process 2
175
20
0
0.188
45
3.535
5.5
0
30%
1.3
50
$0.00
0
$0.15
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
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 in
2
Process Efficiency 62%
Volume of Weld Metal 3.750 in
3
Welder Efficiency 30%
Filler Density lb/in
3
0.283 lb/in
3
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/ft
3
Number of Passes 1
Volume of gas in one 0 ft
3
Labor Cost $108.15
bottle Gas Cost $0.00
Total gas needed 0 ft
3
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 in
2
Process Efficiency 86%
Volume of Weld Metal 3.750 in
3
Welder Efficiency 50%
Filler Density lb/in
3
0.283 lb/in
3
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/ft
3
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
GAS Densities
Carbon Steel 0.283 SAW 99% 70% N/A 0
Stainless Steel 0.29 GMAW (98Ar-2O2) 98% 50% Ar 0.111
Nickel Alloy 0.31 GMAW (75Ar-25CO2) 96% 50% Co2 0.116
GMAW CO2 93% 50% C25 0.115
1 1 FCAW (Gas) 86% 50% 1 4 Single V
1 1 FCAW (Self Shield) 78% 50% 4 1 Single Bev
1 1 SMAW (12" Stick) 59% 30% 1 3 Fillet
SMAW (14" Stick) 0.62 30%
SMAW (18" Stick) 66% 30%
7 5 Sing-V
5 8 Sing-Bev
8 5 Fillet
Interpolation of Deposit Single_V Interpolation of Deposit
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
Alloy Density Process&Welder Eff (%)
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
Cap Hieght
0
0.03125
0.063
0.094
0.125
0.25
0.375
4 4
3 2
3 2
3 3
4 4
3 3
Interpolation of Deposit
Rate Process 1
Interpolation of Deposit
Rate Process 1