KEVOS® MAKEOS · Fabrication
Weldment Cost Estimate (Weld Metal, Arc Time, Labour, Filler and Gas by Run)
For a fabrication with several fillet welds of different sizes and lengths, how much weld metal, arc time and cost does it take, and does it fit my quoted price?
Cost estimate of all the fillet welds on a weldment: for each weld run the weld metal per metre from the leg size and excess, then arc time from the deposition rate, paid time from the operating factor, and labour, filler and shielding gas costs (as the weld cost tool, run by run), summed with any fit-up and handling time, against the price you have quoted for the welding.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Number of weld runs | runs | How many different weld runs (sizes) to include. |
| Weld run 1 | ||
| Fillet leg | mm | Fillet leg size of weld run 1. |
| Total length | m | Total length of weld run 1 on the weldment. |
| Weld run 2 | ||
| Fillet leg | mm | Fillet leg size of weld run 2. |
| Total length | m | Total length of weld run 2. |
| Weld run 3 | ||
| Fillet leg | mm | Fillet leg size of weld run 3. |
| Total length | m | Total length of weld run 3. |
| Weld run 4 | ||
| Fillet leg | mm | Fillet leg size of weld run 4. |
| Total length | m | Total length of weld run 4. |
| Process and rates | ||
| Excess weld metal (convexity, spatter) | % | Allowance for convexity and spatter over the plain triangle. |
| Weld metal density | g/cm³ | Density of the weld metal (7.85 for steel). |
| Deposition rate | kg/h | Weld metal deposited per hour of arc time. |
| Operating factor (arc-on share of paid time) | % | Share of paid time the arc is on. |
| Filler deposition efficiency | % | Share of the filler bought that ends up in the weld. |
| Labour and overhead rate | $/h | Labour and overhead per paid hour. |
| Filler price | $/kg | Price of filler wire or rod. |
| Shielding gas flow | L/min | Shielding gas flow while the arc is on (0 for self-shielded processes). |
| Gas price | $/m³ | Price of shielding gas. |
| Fit-up and handling time | h | Time for fit-up, tacking, turning and handling, charged at the labour rate. |
| Price quoted for the welding | $ | The price allowed for the welding. |
Method and formulas
- Weld metal per metre = ½ leg² × (1 + excess) × density; arc time = mass ÷ deposition rate; paid time = arc time ÷ operating factor (as the weld cost tool).
- Labour = paid time × rate; filler = mass ÷ efficiency × price; gas = arc minutes × flow × gas price.
- Each run multiplied by its length; fit-up time at the labour rate added.
- Example: 1.0752 kg of weld metal, 2.6946 h paid including fit-up, $267 in all.
Limitations
- Fillet welds only; groove welds have a different cross-section.
- Deposition rate and operating factor vary widely with process, position and shop.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Price the welding on a frame or bracket
- Compare leg sizes on cost
- Check a welding quote
Who it is for
- Estimators
- Fabrication engineers
- Welding supervisors
What you get
- Weld metal, arc and paid time by run
- Labour, filler and gas cost
- Total against the quote
Interpreting the result
- Weld metal grows with the square of the leg: one size up on a long run usually costs more than all the short runs.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 1438–1441. Topic reference; no source tables or recommended settings are reproduced.
WORKOS tools are screening and decision-support utilities. Verify important financial, engineering, safety, legal or operational decisions using appropriate professional standards and your organisation’s approved data.
Open the Weldment Cost Estimate (Weld Metal, Arc Time, Labour, Filler and Gas by Run) calculator
