KEVOS® MAKEOS · Fabrication
Fillet Weld Cost per Metre
What does this fillet weld cost per metre in labour, filler and gas?
Weld metal mass, arc time, labour, filler metal and shielding gas cost per metre of fillet weld from leg size, deposition rate, operating factor and prices.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Fillet leg size | mm | Specified leg length of an equal-leg fillet. |
| Excess weld (reinforcement and overwelding) | % | Extra metal from convexity and oversize welds (often 10–30%). |
| Weld metal density | g/cm³ | Density of the deposited metal. |
| Deposition rate | kg/h | Deposition rate for the process, wire size and current (from the consumable maker). |
| Operating factor (arc-on share) | % | Share of the welder’s paid time with the arc on (manual 20–40%, mechanised more). |
| Deposition efficiency | % | Share of filler bought that ends up as weld metal (solid MIG wire about 90–95%, stick electrodes about 60–65%). |
| Labour and overhead rate | AUD/h | Fully loaded labour and overhead cost per hour. |
| Filler price | AUD/kg | Filler metal price per kilogram. |
| Gas flow (0 for no gas) | L/min | Shielding gas flow rate. |
| Gas price | AUD/m³ | Gas cost per cubic metre. |
Method and formulas
- Weld metal = ½ × leg² × (1 + excess) × density (kg/m).
- Arc time = mass ÷ deposition rate; paid time = arc time ÷ operating factor.
- Labour = paid time × rate; filler = mass ÷ efficiency × price; gas = arc time × flow × price.
- Example: a 6 mm fillet costs about $18.80 per metre, mostly labour.
Limitations
- Excludes preparation, fit-up, cleaning, inspection and distortion correction.
- Deposition rate and operating factor vary greatly between shops; use measured values.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Quote welded fabrication
- Compare processes and weld sizes
- Show the cost of oversize welds
Who it is for
- Fabrication supervisors
- Manufacturing engineers
- Estimators
What you get
- Weld metal per metre
- Arc time and paid time per metre
- Labour, filler and gas cost per metre
- Total cost per metre
Interpreting the result
- Weld cost rises with the square of leg size: avoid specifying welds larger than needed.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 1439–1441, 1429–1449. Topic reference; no source tables or recommended settings are reproduced.
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