Legal Statement Year 2006 release

Copyright © 2002 Mark F. Mruczek

Terms
This software was developed by Mark F. Mruczek
If 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 software
is 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 Spreadsheet
If you make any changes to this spreadsheet you are responsible for any and all changes that you make.

Comments
If 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.
mmruczek@atlanticbb.net

Verification
This program was verified the following ways
1 Hand calculations
2 Comparison with other commercial software and publications
Although every effort was made to make this software as accurate and easy to understand as possible, there
is 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 determined
as accurately as possible in order to make sound evaluations of welding cost.

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

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 Drawings

All weld joint drawings were produced usign Arc Works Software developed and distributed by Lincoln Electric Co.
Copyright © 1998 Lincoln Electric Company
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 DETERMINING WELDING COST MAIN MENU
Please Select The Type of Weld Joint You Wish To Evaluate by Pointing to and Clicking on The
Appropriate Picture Below

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

Double Bevel Single-U Single-J Double-J

Compound Single-Bevel Double-U

 DETERMINING WELDING COST FOR A FILLET WELD

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

Senior Welding Engineer Company: NREC Product Form: Plate Page: 1 of 2
Mruczek Welding Engineering Subject: Welding Cost & Time Filler Material ER101TM Choose Units ● English Units Metric Units
Welding process(es) Used: GMAW Trade Name: ESAB For This Sh...
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 in
Filler material Carbon Steel0 Filler material 0
Carbon Steel

Process 0
GMAW (98Ar-2O2) Process 0
GMAW (98Ar-2O2)
Gas Used 90Ar-10Co2 Gas Used 90Ar-10Co2

Amps 250 A Amps 250 A

Volts 30 V Volts 30 V
Wire Feed (in/min) 460 in/min Wire Feed (in/min) 460 in/min
Electrode Diam. (in) 0.05 in Electrode Diam. (in) 0.05 in
Total Length of Weld (ft) 20000 ft Total Length of Weld (ft) 20000 ft
Travel Speed (in/min) 11.0 in/min Travel Speed (in/min) 11.0 in/min
Gas Flow Rate (ft^3/hr) 30 ft^3/hr Gas Flow Rate (ft^3/hr) 30 ft^3/hr
Welder Efficiency 35% Welder Efficiency 35%
Cost Electrode ($/lb) 2.55 $/lb Cost Electrode ($/lb) 2.55 $/lb
Labor/Overhead Rate 25.00 $/hr Labor/Overhead Rate 25.00 $/hr
Cost of Gas 40.00 $/bottle Cost of Gas 40.00 $/bottle
Gas Cylinder Size (ft^3) 330 ft^3 Gas Cylinder Size (ft^3) 330.00 ft^3
Power Cost 0.20 $/kwh Power Cost 0.20 $/kwh
Cost of Flux ($/lb) - $/lb Cost of Flux ($/lb) - $/lb
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.
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 = 1
Last 1 Scroll Down To See Results Flat Convex
 WELDING COST OUTPUT FOR A FILLET WELD
OUTPUT FOR GMAW (98Ar-2O2)
Amount of filler metal needed #VALUE! lbs
Number of passes per joint ~ #VALUE!
Size of fillet weld** 0.248 in
Amount of shielding gas used #VALUE! ft^3
Number of Gas Bottles Required #VALUE!
Actual welding time #VALUE! hr
Labor Cost #VALUE! Labor Cost
Welding Electrode Cost #VALUE! Welding Electrode
Gas Cost #VALUE! Cost
Flux Cost $- Gas Cost
Power Cost #VALUE! Flux Cost
Initial Cost #VALUE! Power Cost
Final Cost #VALUE!
Total cost per ft of weld #VALUE! $/ft
Filler cost per ft of weld #VALUE! $/ft
Flux cost per ft of weld - $/ft
Gas cost per ft of weld #VALUE! $/ft
Labor 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 B10
OUTPUT FOR GMAW (98Ar-2O2)
Amount of filler metal needed #VALUE! lbs
Number of passes per joint ~ #VALUE!
Size of fillet weld** 0.248 in
Amount of shielding gas #VALUE! ft^3
Number of Gas Bottles Required #VALUE!
Actual welding time #VALUE! hr
Labor Cost #VALUE! Labor Cost
Welding Electrode Cost #VALUE! Welding Electrode
Gas Cost #VALUE! Cost
Flux Cost $- Gas Cost
Power Cost #VALUE! Flux Cost
Initial Cost #VALUE! Power Cost
Final Cost #VALUE!
Total cost per ft of weld #VALUE! $/ft
Filler cost per ft of weld #VALUE! $/ft
Flux cost per ft of weld - $/ft
Gas cost per ft of weld #VALUE! $/ft
Labor cost per ft of weld #VALUE! $/ft
#VALUE! Provides A #VALUE! Savings Relative To The #VALUE!
Weld Cost CalcXL

Written By: Mark F. Mruczek

Copyright © 2002 Mark F. Mruczek

Updates since inception

Date Change
16-May-02 Added Update Sheet
Check Spelling
Checked Against Sample Calculations
5-Feb-03 Added Compound Single Bevel Joint to the spreadsheet
Moved all calculations to a separate page
8-Jul-03 Added Double-V, and Double Bevel joint to the spreadsheet
Sample 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 spreadsheet
Updated all weld joint drawing using Arc Works drawing software From the Lincoln Electric company
Updated Tables page to add more base metals, gases and welder efficiencies
27-Apr-04 Corrected errors in cost calculations
Protected Spreadsheet
9-Aug-05 Added Deposition rate page to the spreadsheet
Corrected errors in unit conversion calculations in VB code
Updated Weld Joint Drawings
Sample 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 CalcXL
30-Jan-05 Filed for Copyright
ompany