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Legal Statement Year 2006 releaseCopyright 2002 Mark F. Mruczek
TermsThis software was developed by Mark F. Mruczekf 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 Spreadsheetf you make any changes to this spreadsheet you are responsible for any and all changes that you make.
Commentsf you have comments, corrections or questions about this product send an emailo 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, there
s 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 determias 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 welders day is actually spent welding (4.4 hrs). The balance of tis 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 bused.
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
Weld shops in manufacturing plants normally have established labor and overhead rates for each department. Labor andoverhead rates can vary greatly from plant to plant, and also with location.
mmruczek@atlanticbb.net
Welder Efficiency - Welder Efficiency is the percentage of a welders working day that is actually spent welding.
Labor and overhead are considered jointly in allcalculations in this spreadsheet. Labor is the welders hourly pay rate whincludes their wages and benefits. Overhead includes allocated portions of plant operating and maintenance costs.
mailto:mmruczek@atlanticbb.netmailto:mmruczek@atlanticbb.net7/29/2019 Demo_Weld_Cost_Calc_XL.xls
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Weld Joint DrawingsAll weld joint drawings were produced usign Arc Works Software developed and distributed by Lincoln Electric C
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 TheAppropriate Picture Below
SINGLE - V GROOVEFILLET WELD SINGLE BEVELDOUBLE-V GROOVE
Double Bevel Single-U Single-J Double-J
Compound Single-Bevel Double-U
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DETERMINING WELDING COST FOR A FILLET WELD
Mark Mruczek Project: Base Material: HSLA-80 Date:
Senior Welding Engineer Product Form: Plate Page:
Mruczek Welding Engineering Filler Material ER101TM
Trade Name: ESAB
1/4 fillet weld used for all welding
Please Choose Units before entering data below
Process 1Leg Size (in) 0.250 in Leg Size (in)
Filler material 0 Filler material
Process 0 ProcessGas Used Gas Used
Amps 250 A AmpsVolts 30 V Volts
Wire Feed (in/min) 460 in/min Wire Feed (in/min)Electrode Diam. (in) 0.05 in Electrode Diam. (in)Total Length of Weld (ft) 20000 ft Total Length of Weld (ft)Travel Speed (in/min) 11.0 in/min Travel Speed (in/min)Gas Flow Rate (ft^3/hr) 30 ft^3/hr Gas Flow Rate (ft^3/hr)
Welder Efficiency Welder Efficiency
Cost Electrode ($/lb) 2.55 $/lb Cost Electrode ($/lb)Labor/Overhead Rate 25.00 $/hr Labor/Overhead Rate
Cost of Gas 40.00 $/bottle Cost of GasGas Cylinder Size (ft^3) 330 ft 3 Gas Cylinder Size (ft^3)Power Cost 0.20 $/kwh Power CostCost of Flux ($/lb) - $/lb Cost of Flux ($/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
WELDING COST OUTPUT FOR A FILLET WELD
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 s
EnglishChoose UnitsFor This Sheet
Flat Convex
Carbon Steel
GMAW (98Ar-2O2)
90Ar-10Co2
35%
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OUTPUT FOR GMAW (98Ar-2O2)
Amount of filler metal needed #MACRO? lbsNumber of passes per joint ~ #MACRO?Size of fillet weld** 0.248 inAmount of shielding gas used #MACRO? ft^3Number of Gas Bottles Required #MACRO?Actual welding time #MACRO? hrLabor Cost #MACRO?Welding Electrode Cost #MACRO?Gas Cost #MACRO?Flux Cost $-Power Cost #MACRO?Initial Cost #MACRO?Final Cost #MACRO?Total cost per ft of weld #MACRO? $/ftFiller cost per ft of weld #MACRO? $/ftFlux cost per ft of weld - $/ftGas cost per ft of weld #MACRO? $/ftLabor cost per ft of weld #MACRO? $/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 B1OUTPUT FOR GMAW (98Ar-2O2)
Amount of filler metal needed #MACRO? lbsNumber of passes per joint ~ #MACRO?Size of fillet weld** 0.248 inAmount of shielding gas #MACRO? ft^3Number of Gas Bottles Required #MACRO?
Actual welding time #MACRO? hrLabor Cost #MACRO?Welding Electrode Cost #MACRO?Gas Cost #MACRO?Flux Cost $-Power Cost #MACRO?Initial Cost #MACRO?Final Cost #MACRO?Total cost per ft of weld #MACRO? $/ftFiller cost per ft of weld #MACRO? $/ftFlux cost per ft of weld - $/ftGas cost per ft of weld #MACRO? $/ftLabor cost per ft of weld #MACRO? $/ft
#MACRO? Provides A #MACRO? Savings Relative To The ###
Labor
WeldinCost
Gas C
Flux C
Power
Labor
WeldinCost
Gas C
Flux C
Power
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Weld Cost CalcXL
Written By: Mark F. MruczekCopyright 2002 Mark F. Mruczek
Updates since inception
Date Change16-May-02Added Update Sheet
Check Spelling
Checked Against Sample Calculations
5-Feb-03Added Compound Single Bevel Joint to the spreadsheetMoved all calculations to a separate page
8-Jul-03Added Double-V, and Double Bevel joint to the spreadsheetSample Values Entered
10-Oct-03Added Units pageAdded units conversion VB code to each sheet
17-Jan-04Added Single-U, Single-J, and Double-J Joints to the spreadsheetUpdated all weld joint drawing using Arc Works drawing software From the Lincoln Electric comp
Updated Tables page to add more base metals, gases and welder efficiencies
27-Apr-04 Corrected errors in cost calculationsProtected Spreadsheet
9-Aug-05Added Deposition rate page to the spreadsheetCorrected 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 CalcXL30-Jan-05 Filed for Copyright
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