Legal Statement Year 2006 releaseCopyright © 2002 Mark F. Mruczek

TermsThis software was developed by Mark F. MruczekIf you use this product you agree to the following terms and conditions:

1 The user uses this software at their own risk.2 This notice must be included with all copies made.3 This product is used "as is" without warrantees or liability. It is your responsibility

to know how to use this software. Any job/weldment quoted with this softwareis the users responsibility. Mruczek's Welding Engineering does not guarantee the accuracy of this product.

4 All risk associated with this products use is assumed by the user.5 All cost calculated with this spreadsheet are for welding only. It does not take into consideration machining cost,

material cost (other than welding material)

Changes To SpreadsheetIf you make any changes to this spreadsheet you are responsible for any and all changes that you make.

CommentsIf you have comments, corrections or questions about this product send an email to mmruczek@atlanticbb.net. I will try to answer all e-mails in a timely manner.

VerificationThis program was verified the following ways

1 Hand calculations2 Comparison with other commercial software and publications

Although every effort was made to make this software as accurate and easy to understand as possible, thereis no way to guarantee it's accuracy. There are assumptions that must be made concerning welder and process efficiency.Process efficiency is built into the program and the information was obtained from numerous publications.Welder efficiency is supplied by the user. This is one of the most basic factors in the cost calculations and must be determinedas accurately as possible in order to make sound evaluations of welding cost.

Welder Efficiency

A 45% (.45) operating factor means that only 45% of the welder’s day is actually spent welding (4.4 hrs). The balance of time is spent installing a new electrode or wire, cleaning slag, positioning the weldment, cleaning spatter from the welding gun, preparing the joint, moving parts, coffee break etc. If the actual operating factor is not known, the following averages can be used.

30% may be used with the shielded metal arc welding process(SMAW)50% may be used with the Gas metal arc welding process (GMAW)45% may be used with the FluxCored Arc Welding process (FCAW)45%-50% may be used with the Submerged Arc Welding process (SAW)50% may be used with any automatic Welding process

Labor and Overhead Rates

mmruczek@atlanticbb.net

Welder Efficiency - Welder Efficiency is the percentage of a welder’s working day that is actually spent welding.

Labor and overhead are considered jointly in all calculations in this spreadsheet.  Labor is the welder’s hourly pay rate which includes their wages and benefits.  Overhead includes allocated portions of plant operating and maintenance costs.  

Weld shops in manufacturing plants normally have established labor and overhead rates for each department. Labor and overhead rates can vary greatly from plant to plant, and also with location.

Weld Joint DrawingsAll weld joint drawings were produced usign Arc Works Software developed and distributed by Lincoln Electric Co.Copyright © 1998 Lincoln Electric Company

is no way to guarantee it's accuracy. There are assumptions that must be made concerning welder and process efficiency.

Welder efficiency is supplied by the user. This is one of the most basic factors in the cost calculations and must be determined

A 45% (.45) operating factor means that only 45% of the welder’s day is actually spent welding (4.4 hrs). The balance of time is spent installing a new electrode or wire, cleaning slag, positioning the weldment, cleaning spatter from the welding gun, preparing the joint, moving parts, coffee break etc. If the actual operating factor is not known, the following averages can be

calculations in this spreadsheet.  Labor is the welder’s hourly pay rate which

All weld joint drawings were produced usign Arc Works Software developed and distributed by Lincoln Electric Co.

DETERMINING WELDING COST MAIN MENUPlease Select The Type of Weld Joint You Wish To Evaluate by Pointing to and Clicking on The Appropriate Picture Below

Double Bevel Single-U Single-J Double-J

Compound Single-Bevel Double-U

SINGLE - V GROOVE FILLET WELD SINGLE BEVEL DOUBLE-V GROOVE

DETERMINING WELDING COST FOR A FILLET WELD

Mark Mruczek Project: Base Material: HSLA-80 Date: 01/16/06

Senior Welding Engineer Product Form: Plate Page: 1 of 2Mruczek Welding Engineering Filler Material ER101TM

Trade Name: ESAB

1/4 fillet weld used for all welding

Please Choose Units before entering data below

Process 1 Process 2

Leg Size (in) 0.250 in Leg Size (in) 0.25 inFiller material 0 Filler material 0

Process 0 Process 0Gas Used Gas Used

Amps 250 A Amps 250 AVolts 30 V Volts 30 V

Wire Feed (in/min) 460 in/min Wire Feed (in/min) 460 in/minElectrode Diam. (in) 0.045 in Electrode Diam. (in) 0.045 inTotal Length of Weld (ft) 20000 ft Total Length of Weld (ft) 20000 ftTravel Speed (in/min) 11.0 in/min Travel Speed (in/min) 11.0 in/minGas Flow Rate (ft^3/hr) 30 ft^3/hr Gas Flow Rate (ft^3/hr) 30 ft^3/hr

Welder Efficiency Welder Efficiency

Cost Electrode ($/lb) 2.55 $/lb Cost Electrode ($/lb) 2.55 $/lbLabor/Overhead Rate 25.00 $/hr Labor/Overhead Rate 25.00 $/hrCost of Gas 40.00 $/bottle Cost of Gas 40.00 $/bottleGas Cylinder Size (ft^3) 330 ft^3 Gas Cylinder Size (ft^3) 330.00 ft^3Power Cost 0.20 $/kwh Power Cost 0.20 $/kwhCost of Flux ($/lb) - $/lb Cost of Flux ($/lb) - $/lb

In other words welders will typically produce a weld that is 10% larger than what is required.Fillet welds are assumed to be convex rather than flat for cost calculations (See Drawings to the right.

Units = 1Last 1 Scroll Down To See Results

Company: NREC

Subject: Welding Cost & Time Welding process(es) Used: GMAW

Leg Size- The leg size shown above is what is required. For cost calculations 10% is added to the size shown. This is consistant with normal shop practices.

Flat Convex

English Units Metric UnitsChoose UnitsFor This Sh...

WELDING COST OUTPUT FOR A FILLET WELD OUTPUT FOR GMAW (98Ar-2O2)

Amount of filler metal needed #VALUE! lbsNumber of passes per joint ~ #VALUE!Size of fillet weld** 0.248 inAmount of shielding gas used #VALUE! ft^3Number of Gas Bottles Required #VALUE!Actual welding time #VALUE! hrLabor Cost #VALUE!Welding Electrode Cost #VALUE!Gas Cost #VALUE!Flux Cost $ - Power Cost #VALUE!Initial Cost #VALUE!Final Cost #VALUE!Total cost per ft of weld #VALUE! $/ftFiller cost per ft of weld #VALUE! $/ftFlux cost per ft of weld - $/ftGas cost per ft of weld #VALUE! $/ftLabor cost per ft of weld #VALUE! $/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 Cell B10OUTPUT FOR GMAW (98Ar-2O2)

Amount of filler metal needed #VALUE! lbsNumber of passes per joint ~ #VALUE!Size of fillet weld** 0.248 inAmount of shielding gas #VALUE! ft^3Number of Gas Bottles Required #VALUE!Actual welding time #VALUE! hrLabor Cost #VALUE!Welding Electrode Cost #VALUE!Gas Cost #VALUE!Flux Cost $ - Power Cost #VALUE!Initial Cost #VALUE!Final Cost #VALUE!Total cost per ft of weld #VALUE! $/ftFiller cost per ft of weld #VALUE! $/ftFlux cost per ft of weld - $/ftGas cost per ft of weld #VALUE! $/ftLabor cost per ft of weld #VALUE! $/ft

Labor Cost

Welding Electrode Cost

Gas Cost

Flux Cost

Power Cost

Labor Cost

Welding Electrode Cost

Gas Cost

Flux Cost

Power Cost

#VALUE! Provides A #VALUE! Savings Relative To The #VALUE!

Labor Cost

Welding Electrode Cost

Gas Cost

Flux Cost

Power Cost

Weld Cost CalcXL

Written By: Mark F. MruczekCopyright © 2002 Mark F. Mruczek

Updates since inception

Date Change16-May-02 Added Update Sheet

Check SpellingChecked Against Sample Calculations

5-Feb-03 Added Compound Single Bevel Joint to the spreadsheetMoved all calculations to a separate page

8-Jul-03 Added Double-V, and Double Bevel joint to the spreadsheetSample Values Entered

10-Oct-03 Added Units page Added units conversion VB code to each sheet

17-Jan-04 Added Single-U, Single-J, and Double-J Joints to the spreadsheetUpdated all weld joint drawing using Arc Works drawing software From the Lincoln Electric companyUpdated Tables page to add more base metals, gases and welder efficiencies

27-Apr-04 Corrected errors in cost calculationsProtected Spreadsheet

9-Aug-05 Added Deposition rate page to the spreadsheetCorrected errors in unit conversion calculations in VB codeUpdated Weld Joint DrawingsSample Calcs Ran-Verification Complete Added Notes to Fillet weld page and fillet weld drawing showing flat and convex beads

12//14/2005 Changed Name from Weld Cost Rev 3 to Weld Cost CalcXL30-Jan-05 Filed for Copyright

Updated all weld joint drawing using Arc Works drawing software From the Lincoln Electric company