DETERMINING WELDING COST FOR A FILLET WELD

Mark Mruczek Welding Engineer

Project: Company: Subject:

Welding Cost

Welding process Used:

Base Material: Product Form: Filler Material Trade Name:

A 516 Plate

Date: Page:

08/07/02 1 of 2

Leg Size (in) Filler material

Process 1 0.250
Carbon Steel

Leg Size (in) Filler material

Process 2 0.250
Carbon Steel

SMAW (14" Stick) Process Gas Used N/A Amps 200 Volts 21 Wire Feed (in/min) 0 Wire Diam. (in) 0.19 Total Length of Weld(ft) 10 Travel Speed (ipm) 6 Gas Flow Rate (cfh) 0 Welder Efficiency 30% Cost Electrode($/lb) 1.3 Labor Rate ($/hr) 60 Cost of Gas (per bottle) $0.00 Weight of gas (1 bottle) (lb) 0 Power Cost ($/kilowatt-hr) $0.15

FCAW (Gas) Process Gas Used Co2 Amps 200 Volts 21 Wire Feed (in/min) 190 Wire Diam. (in) 0.05 Total Length of Weld(ft) 10 Travel Speed (ipm) 8 Gas Flow Rate (cfh) 40 Welder Efficiency 50% Cost Electrode($/lb) 2.5 Labor Rate ($/hr) 60 Cost of Gas (per bottle) $70.00 Weight of gas (1 bottle) (lb) 50 Power Cost ($/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 Welding Wire Cost Gas Cost Power Cost Initial Cost Final Cost $108.15 $2.60 $0.00 $0.35 $111.10 $127.80

Labor Cost 97%

Labor Cost Welding Wire Cost Gas Cost Power Cost

Power Cost 0% Welding Wire Cost 2% 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 Labor Cost 86% Labor Cost Actual welding time 0.78 hr

Labor Cost Welding Wire Cost Gas Cost Power Cost Initial Cost Final Cost

$46.80 $5.00 $2.55 $0.25 $54.60 $62.80

Welding Wire Cost Gas Cost Power Cost

Welding Wire Cost 9% Power Cost 0% Gas Cost 5%

Cost per ft of weld

$5.46 $/ft

Welding Wire Cost 9% Power Cost 0% Gas Cost 5%

Cost per foot filler metal Cost per foot of gas Cost of Labor per foot

$0.50 $/ft $0.26 $/ft $4.68 $/ft

DETERMINING WELDING COST FOR A SINGLE-V GROOVE WELD

Mark Mruczek Welding Engineer
Project: Company: Subject:

Welding Cost

Welding process Used:

Base Material: Product Form: Filler Material Trade Name:

A 516 Plate E7018

Date: Page:

08/07/02 1 of 2

Thickness (in) Height of "h" (in) Root Opening (in) Root Face(in) Filler material

Process 1 0.625 0.063 0.094 0.063

Carbon Steel

Thickness (in) Height of "h" (in) Root Opening (in) Root Face(in) Filler material

Process 2 0.625 0.063 0.094 0.063

Carbon Steel

SMAW (14" Stick) Process Gas Used N/A Amps 200 Volts 22 Wire Feed (in/min) 0 Wire Diam. (in) 0.19 Joint Angle 60 Total Length of Weld(ft) 1000 Travel Speed (ipm) 6 Gas Flow Rate (cfh) 0 Welder Efficiency 30% Cost Electrode($/lb) 1.26 Labor Rate ($/hr) 60 Cost of Gas (per bottle) $0.00 Weight of gas in one bottle (lb) 0 Power Cost ($/kilowatt-hr) $0.10

FCAW (Gas) Process Gas Used C25 Amps Volts Wire Feed (in/min) Wire Diam. (in) Joint Angle Total Length of Weld(ft) Travel Speed (ipm) Gas Flow Rate (cfh) Welder Efficiency Cost Electrode($/lb) Labor Rate ($/hr) Cost of Gas (per bottle) Weight of gas in one bottle (lb) Power Cost ($/kilowatt-hr)

WELDING COST OUTPUT FOR A SINGLE-V GROOVE WELD

OUTPUT FOR SMAW (14" Stick) Amount of weld wire needed 1492.13 lb Number of passes per joint ~ 6 Amount of shielding gas 0.00 ft^3 bottles = N/A Actual welding time 1344.26 hr Labor Cost Welding Wire Cost Gas Cost Power Cost Initial Cost Final Cost $50,006.52 $1,880.08 $0.00 $177.44 $52,064.05 $59,873.65
Welding Wire Cost 4% Power Cost 0%

Labor Cost 96%

Labor Cost Welding Wire Cost Gas Cost Power Cost

Cost per ft of weld Cost per foot filler metal Cost per foot of gas Cost of Labor per foot OUTPUT FOR FCAW (Gas) Amount of weld wire needed Number of passes per joint ~ Amount of shielding gas Actual welding time Labor Cost Welding Wire Cost Gas Cost Power Cost Initial Cost Final Cost

$52.06 $/ft $1.88 $/ft $0.00 $/ft $50.01 $/ft

1075.72 lb 9 6196.31 ft^3 bottles = 14 354.07 hr

Welding Wire Cost 11%

Gas Cost 5% Power Cost 0%

$18,270.25 $2,420.37 $1,068.86 $84.98 $21,844.47 $25,121.13

Labor Cost Welding Wire Cost Gas Cost Power Cost

Cost per ft of weld Cost per foot filler metal Cost per foot of gas

$21.84 $/ft $2.42 $/ft $1.07 $/ft

Labor Cost 84%

Labor Cost 84%

Cost of Labor per foot

$18.27 $/ft

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 96%

Labor Cost Welding Wire Cost Gas Cost Power Cost

Welding Wire Cost 4% Power Cost 0%

Welding Wire Cost 11%

Gas Cost 5% Power Cost 0%

Labor Cost Welding Wire Cost Gas Cost Power Cost

Labor Cost 84%

Labor Cost 84%

DETERMINING WELDING COST FOR A SINGLE-BEVEL GROOVE WELD

Mark Mruczek Welding Engineer
Project: Company: Subject:

Welding Cost SMAW + GMAW

Welding process Used:

Base Material: Product Form: Filler Material Trade Name:

A 516 Plate E7018 Lincoln

Date: Page:

05/22/02 1 of 2

Thickness (in) Height of "h" (in) Root Opening (in) Root Face(in) Filler material

Process 1 2.25 0.09 0.13 0.09

Carbon Steel

Thickness (in) Height of "h" (in) Root Opening (in) Root Face(in) Filler material

Process 2 2.25 0.09 0.13 0.09

Carbon Steel

Process FCAW (Gas) Gas Used C25 Amps Volts Wire Feed (in/min) Wire Diam. (in) Joint Angle Total Length of Weld(ft) Travel Speed (ipm) Gas Flow Rate (cfh) Welder Efficiency Cost Electrode($/lb) Labor Rate ($/hr) Cost of Gas (per bottle) Weight of gas in one bottle Power Cost ($/kilowatt-hr)

200 21 225 0.05 45 3.54 9 35 50% 2.45 50 $50.00 50 $0.15

SMAW (14" Stick) Process Gas Used N/A Amps Volts Wire Feed (in/min) Wire Diam. (in) Joint Angle Total Length of Weld(ft) Travel Speed (ipm) Gas Flow Rate (cfh) Welder Efficiency Cost Electrode($/lb) Labor Rate ($/hr) Cost of Gas (per bottle) Weight of gas in one bottle (lb) Power Cost ($/kilowatt-hr)

WELDING COST OUTPUT FOR A SINGLE-BEVEL GROOVE WELD

OUTPUT FOR FCAW (Gas) Amount of weld wire needed Number of passes per joint ~ Amount of shielding gas Actual welding time Labor Cost Welding Wire Cost Gas Cost Power Cost Initial Cost Final Cost

38.37 lb 100 165.52 ft^3 bottles = 1 9.46 hr $406.70 $94.01 $19.03 $2.98 $522.72 $601.13

Gas Cost 4% Power Cost 1% Welding Wire Cost 18%

Labor Cost Welding Wire Cost Gas Cost Power Cost

Cost per ft of weld Cost per foot filler metal Cost per foot of gas Cost of Labor per foot

$147.87 $/ft $26.59 $/ft $5.38 $/ft $115.05 $/ft

Labor Cost 78%

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 Welding Wire Cost Gas Cost Power Cost Initial Cost Final Cost $3,000.00 $70.20 $0.00 $0.28 $3,081.00 $3,543.15

Labor Cost 98%

Labor Cost Welding Wire Cost Gas Cost Power Cost

Power Cost 0% Welding Wire Cost 2%

Cost per ft of weld Cost per foot filler metal Cost per foot of gas Cost of Labor per foot

$871.57 $/ft $19.86 $/ft $0.00 $/ft $848.66 $/ft

Power Cost 0% Welding Wire Cost 2%

Process 2

Carbon Steel SMAW (14" Stick) N/A

175 20 0 0.188 45 3.54 5.5 0 30% 1.3 50 $0.00 0 $0.15

Gas Cost 4% Power Cost 1% Welding Wire Cost 18%

Labor Cost Welding Wire Cost Gas Cost Power Cost

Labor Cost 78%

Labor Cost 98%

Labor Cost Welding Wire Cost Gas Cost Power Cost

Power Cost 0% Welding Wire Cost 2%

Power Cost 0% Welding Wire Cost 2%

distance "d" = Distance "R" = Distance c1 = Distance "c" = Filler Density lb/in^3 Area Cap "C" Weld Metal Weight "C" Area Rectangle "A" Weld Metal Weight "A" Area of two Triangles "B" Weld Metal Weight "B" Total Weld Metal Weight Amount of Welding Wire Deposition Rate Total Power Cost

0.56 in 0.6495 in 0.6495 in 0.7433 in 0.28 lb/in^3 0.0311 in^2 0.1058 lb/ft 0.0586 in^2 0.199 lb/ft 0.1827 in^2 0.620 lb/ft 0.9251 lb/ft 1492.13 lb 3.70 Lb/hr $177.44

CALCULATIONS PROCESS 1 Single-V Groove Process Efficiency 62% Process Welder Efficiency 30% Bottles of gas needed Arc Time 403.28 hr Radius of cap "r" Total welding time 1344.26 hr Deposited Weld Metal Wt. Density of gas 0 lb/ft^3 Volume of gas in one 0.00 ft^3 bottle Total gas needed 0.00 ft^3 Labor Cost $50,006.52 Gas Cost $0.00 Cost Electrode $1,880.08 Total Cost $52,064.05 Final Cost $7,809.61 $59,873.65 Heat Input 44 Number of Passes 6

SMAW (14" Stick) N/A 1.14 925

distance "d" = Distance "R" = Distance c1 = Distance "c" = Filler Density lb/in^3 Area Cap "C" Weld Metal Weight "C" Area Rectangle "A" Weld Metal Weight "A" Area of two Triangles "B" Weld Metal Weight "B" Total Weld Metal Weight Amount of Welding Wire Deposition Rate Total Power Cost

0.56 in 0.6495 in 0.6495 in 0.7433 in 0.28 lb/in^3 0.0311 in^2 0.1058 lb/ft 0.0586 in^2 0.199 lb/ft 0.1827 in^2 0.620 lb/ft 0.9251 lb/ft 1075.72 lb 6.08 Lb/hr $84.98

CALCULATIONS PROCESS 2 Single-V Groove Process Efficiency 86% Process Welder Efficiency 50% Bottles of gas needed Arc Time 177.04 hr Radius of cap "r" Total welding time 354.07 hr Deposited Weld Metal Wt. Density of gas 0.12 lb/ft^3 Volume of gas in one 434.78 ft^3 bottle Total gas needed 6196.31 ft^3 Labor Cost $18,270.25 Gas Cost $1,068.86 Cost Electrode $2,420.37 Total Cost $21,844.47 Final Cost $3,276.67 $25,121.13 Heat Input 30 Number of Passes 9

FCAW (Gas) 14 1.14 925.12

distance "d" = Distance "R" = Distance c1 = Distance "c" = Filler Density lb/in^3 Area Cap "C" Weld Metal Weight "C" Area Rectangle "A" Weld Metal Weight "A" Area of two Triangles "B" Weld Metal Weight "B" Total Weld Metal Weight Amount of Welding Wire Deposition Rate Total Power Cost

2.16 in 3.0494 in 2.1563 in 2.2813 in 0.28 lb/in^3 0.1428 in^2 0.4848 lb/ft 0.2813 in^2 0.955 lb/ft 2.3247 in^2 7.895 lb/ft 9.335 lb/ft 38.37 lb 8.11 Lb/hr $2.98

CALCULATIONS PROCESS 1 Single-Bevel Groove Process Efficiency 86% Process Welder Efficiency 50% Bottles of gas needed Arc Time 4.73 hr Radius of cap "r" Total welding time 9.46 hr Beta Density of gas 0.12 lb/ft^3 Deposited Weld Metal Wt. Volume of gas in one 434.78 ft^3 bottle Total gas needed 165.52 ft^3 Labor Cost $406.70 Gas Cost $19.03 Cost Electrode $94.01 Total Cost $522.72 Final Cost $78.41 $601.13 Heat Input 28 Number of Passes 100 CALCULATIONS PROCESS 2 Single-Bevel Groove Process Efficiency 62% Process Welder Efficiency 30% Bottles of gas needed Arc Time 18.00 hr Radius of cap "r" Total welding time 60.00 hr Beta Density of gas 0 lb/ft^3 Deposited Weld Metal Wt. Volume of gas in one 0.00 ft^3 bottle Total gas needed 0.00 ft^3 Labor Cost $3,000.00 Gas Cost $0.00 Cost Electrode $70.20 Total Cost $3,081.00 Final Cost $3,543.15 Heat Input 38.18 Number of Passes 73

FCAW (Gas) 1 6.986 45 33.00

distance "d" = Distance "R" = Distance c1 = Distance "c" = Filler Density lb/in^3 Area Cap "C" Weld Metal Weight "C" Area Rectangle "A" Weld Metal Weight "A" Area of two Triangles "B" Weld Metal Weight "B" Total Weld Metal Weight Amount of Welding Wire Deposition Rate Total Power Cost

2.16 in 3.0494 in 2.1563 in 2.2813 in 0.28 lb/in^3 0.1428 in^2 0.4848 lb/ft 0.2813 in^2 0.955 lb/ft 2.3247 in^2 7.895 lb/ft 9.335 lb/ft 54.00 lb 3.000 Lb/hr $10.80

SMAW (14" Stick) N/A 6.986 45 33.00

Area of Fillet Weld

CALCULATIONS PROCESS 1 Fillet Weld 0.0313 in2 Process Efficiency

62%

Volume of Weld Metal 3.750 in3 Filler Density lb/in3 0.28 lb/in3 Total Weld Metal Weight 0.106 lb/ft Amount of Welding Wire 2.000 lb Deposition Rate 3.700 lb/hr Density of gas 0 lb/ft3 Volume of gas in one 0 ft3 bottle Total gas needed 0 ft3 Bottles of gas needed N/A Process SMAW (14" Stick)

Welder Efficiency Arc Time Total welding time Heat Input Fillet Weld Size Number of Passes Labor Cost Gas Cost Cost Electrode Total Power Cost Total Cost Final Cost

30% 0.541 hr 1.802 hr 42 kJ/in 0.290 in 1 $108.15 $0.00 $2.60 $0.35 $111.10 $127.80

CALCULATIONS PROCESS 2 Fillet Weld Area of Fillet Weld 0.0313 in2 Process Efficiency 3 Volume of Weld Metal 3.750 in Welder Efficiency Filler Density lb/in3 0.28 lb/in3 Arc Time Total Weld Metal Weight 0.106 lb/ft Total welding time Amount of Welding Wire 2.000 lb Heat Input Deposition Rate 5.13 lb/hr Fillet Weld Size 3 Density of gas 0.12 lb/ft Number of Passes 3 Volume of gas in one 431.03 ft Labor Cost bottle Gas Cost Total gas needed 15.59 ft3 Cost Electrode Bottles of gas needed 1 Total Power Cost Process FCAW (Gas) Total Cost Final Cost

86% 50% 0.390 hr 0.780 hr 31.5 kJ/in 0.251 in 1 $46.80 $2.55 $5.00 $0.25 $54.60 $62.80

SMAW (14" Stick) in lb

FCAW (Gas) in lb

FCAW (Gas) in lb

SMAW (14" Stick) in lb

Alloy Density Carbon Steel 0.28 Stainless Steel 0.29 Nickel Alloy 0.31 1 1 1 1 1 1

Interpolation of Deposit Rate Process 1 0.000 0.000 0.000 0.000 6.076 0.000 0.000 0.000 6.076

5 0 0 0 0 200 0 0 0

Process&Welder Eff (%) SAW 99% 98% GMAW (98Ar-2O2) 96% GMAW (75Ar-25CO2) GMAW CO2 93% FCAW (Gas) 86% 78% FCAW (Self Shield) 59% SMAW (12" Stick) 0.62 SMAW (14" Stick) 66% SMAW (18" Stick) 8 5 Sing-V 5 8 Sing-Bev 8 5 Fillet Single_V Deposition Rates SMAW 8 110 1.8 0 125 2 0 150 2.6 0 175 3 0 200 3.7 200 225 4.2 0 275 7 0 325 9 0 400 10

70% 50% 50% 50% 50% 50% 30% 30% 30%

GAS Densities N/A Ar Co2 C25 1 4 1

0 0.11 0.12 0.12 4 Single V 1 Single Bev 3 Fillet

Interpolation of Deposit Rate Process 1 0.000 0.000 0.000 0.000 3.700 0.000 0.000 0.000 3.700

Cap Hieght 0 0.03 0.063 0.094 0.125 0.25 0.38 2 3 3 3 4 3

Weld Size 0.13 0.19 0.250 0.313 0.375 0.438 0.500 0.56 0.625 0.688 0.750

Interpolation of Deposit Rate Process 1 0.000 0.000 0.000 3.000 0.000 0.000 0.000 0.000 3.000

8 0 0 0 175 0 0 0 0

Single Bevel Deposition Rates SMAW 110 1.8 125 2 150 2.6 175 3 200 3.7 225 4.2 275 7 325 9 400 10

5 0 0 0 0 200 0 0 0

Interpolation of Deposit Rate Process 1 0.000 0.000 0.000 0.000 8.114 0.000 0.000 0.000 8.114

Single V Single Bevel Fillet Weld

0.81 0.875 0.938 1.000 1.13 1.25 1.38 1.5 1.56 1.63 1.75 1.81 1.88 2 2.13 2.25 2.38 2.5 2.56 2.63 2.75 2.81 2.88 3 3.13 3.25 3.38 3.5 3.56 3.63 3.75 3.81 9 27 3

Interpolation of Deposit Rate Process 1 0.000 0.000 0.000 0.00 3.700 0.000 0.000 0.000 3.700

8 0 0 0 0 200 0 0 0

Fillet Weld Deposition Rates SMAW 110 1.8 125 2 150 2.6 175 3 200 3.7 225 4.2 275 7 325 9 400 10

5 0 0 0 0 200 0 0 0

Interpolation of Deposit Rate Process 1 0 0 0 0 5.131 0 0 0 5.131

9 27 3

3 2 2 3 4 3