Demo_Weld_Cost_Calc_XL.xls

7/29/2019 Demo_Weld_Cost_Calc_XL.xls

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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 [email protected]. 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.

[email protected]

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:[email protected]:[email protected]


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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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Demo_Weld_Cost_Calc_XL.xls

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