Terms This software was developed by Mark F. Mruczek If you use this product you agree to the followig ter!s ad coditios" # The user uses this software at their ow risk. 2 This otice !ust be icluded with all copies !ade. $ This product is used %as is% without warratees or liability. It is your resposibility to kow how to use this software. &y 'ob(weld!et )uoted with this software is the users resposibility. Mruczek*s +eldig ,gieerig does ot guaratee the accuracy of this product. - &ll risk associated with this products use is assu!ed by the user. . &ll cost calculated with this spreadsheet are for weldig oly. It does ot take ito cosideratio !achiig cost/ !aterial cost 0other tha weldig !aterial1 Changes To Spreadsheet If you !ake ay chages to this spreadsheet you are resposible for ay ad all chages that you !ake. Comments If you have co!!ets/ correctios or )uestios about this product sed a e!ail to !!ruczek2atlaticbb.et. I will try to aswer all e3!ails i a ti!ely !aer. Verification This progra! was verified the followig ways # 4ad calculatios 2 Co!pariso with other co!!ercial software ad publicatios <hough every effort was !ade to !ake this software as accurate ad easy to uderstad as possible/ there is o way to guaratee it*s accuracy. There are assu!ptios that !ust be !ade cocerig welder ad process efficiecy. 5rocess efficiecy is built ito the progra! ad the ifor!atio was obtaied fro! u!erous publicatios. +elder efficiecy is supplied by the user. This is oe of the !ost basic factors i the cost calculatios ad !ust be deter!ied as accurately as possible i order to !ake soud evaluatios of weldig cost. Welder Efficiency & -.6 0.-.1 operatig factor !eas that oly -.6 of the welder7s day is actually spet weldig 0-.- hrs1. The balace of ti!e is spet istallig a ew electrode or wire/ cleaig slag/ positioig the weld!et/ cleaig spatter fro! the weldig gu/ preparig the 'oit/ !ovig parts/ coffee break etc. If the actual operatig factor is ot kow/ the followig averages ca be used. $06 !ay be used with the shielded !etal arc weldig process08M&+1 .06 !ay be used with the 9as !etal arc weldig process 09M&+1 -.6 !ay be used with the Flu:Cored &rc +eldig process 0FC&+1 -.63.06 !ay be used with the 8ub!erged &rc +eldig process 08&+1 .06 !ay be used with ay auto!atic +eldig process Labor and Oerhead !ates !!ruczek2atlaticbb.et Welder Efficiency " +elder ,fficiecy is the percetage of a welder7s workig day that is actually spet weldig. ;abor ad overhead are cosidered 'oitly i all calculatios i this spreadsheet. ;abor is the welder7s hourly pay rate which icludes their wages ad beefits. <verhead icludes allocated portios of plat operatig ad !aiteace costs. +eld shops i !aufacturig plats or!ally have established labor ad overhead rates for each depart!et. ;abor ad overhead rates ca vary greatly fro! plat to plat/ ad also with locatio. Weld #oint $ra%ings All weld joint drawings were produced usign Arc Works Software developed and distributed by Lincoln Electric Co. Copyright !!" Lincoln Electric Co#pany +elder efficiecy is supplied by the user. This is oe of the !ost basic factors i the cost calculatios ad !ust be deter!ied & -.6 0.-.1 operatig factor !eas that oly -.6 of the welder7s day is actually spet weldig 0-.- hrs1. The balace of ti!e preparig the 'oit/ !ovig parts/ coffee break etc. If the actual operatig factor is ot kow/ the followig averages ca be calculatios i this spreadsheet. ;abor is the welder7s hourly pay rate which All weld joint drawings were produced usign Arc Works Software developed and distributed by Lincoln Electric Co. DETERMINING WELDING COST MAIN MENU &lease Select The Type of Weld #oint Yo' Wish To Eal'ate by &ointing to and Clic(ing on The )ppropriate &ict're *elo% =ouble >evel 8igle3? 8igle3@ =ouble3@ Co!poud 8igle3>evel =ouble3? SINGLE - V GROOVE FILLET WELD SINGLE BEVEL DOUBLE-V GROOVE DETERMINING WELDING COST FOR A FILLET WELD Mark Mruczek &ro+ect, *ase -aterial, 48;&3A0 $ate, 0#(#B(0B 8eior +eldig ,gieer &rod'ct .orm, 5late &age, # of 2 Mruczek +eldig ,gieerig .iller -aterial ,C#0#TM Trade /ame, ,8&> #(- fillet weld used for all weldig 5lease Choose ?its before eterig data below &rocess 0 &rocess 2 Leg Si1e 2in3 -.000 !! Leg Si1e 2in3 B.$. !! .iller material 0 .iller material 0 &rocess 0 &rocess 0 4as 5sed 4as 5sed )mps 2.0 & )mps 2.0 & Volts $0 D Volts $0 D Wire .eed 2m6min3 ##.BA- !(!i Wire .eed 2m6min3 ##.BA- !(!i Electrode $iam7 2mm3 #.#-$ !! Electrode $iam7 2mm3 #.#-$ !! Total Length of Weld 2m3 B0EB ! Total Length of Weld 2m3 B0EB ! Trael Speed 2m6min3 0.$ !(!i Trael Speed 2m6min3 0.$ !(!i 4as .lo% !ate 2L6min3 #- ;(!i 4as .lo% !ate 2L6min3 #- ;(!i Welder Efficiency Welder Efficiency Cost Electrode 286(g3 ..B2 F(kg Cost Electrode 286(g3 ..B2 F(kg Labor6Oerhead !ate 2..00 F(hr Labor6Oerhead !ate 2..00 F(hr Cost of 4as -0.00 F(bottle Cost of 4as -0.00 F(bottle 4as Cylinder Si1e 2m9:3 E.$--2A !G$ 4as Cylinder Si1e 2m9:3 E.$- !G$ &o%er Cost 0.20 F(kwh &o%er Cost 0.20 F(kwh Cost of .l'; 286(g3 3 F(kg Cost of .l'; 286(g3 3 F(kg I other words welders will typically produce a weld that is #06 larger tha what is re)uired. Fillet welds are assu!ed to be cove: rather tha flat for cost calculatios 08ee =rawigs to the right. ?its H 2 ;ast 2 Scroll $own %o See &esults Company, /!EC S'b+ect, Welding Cost < Time Welding process2es3 5sed, 4-)W Leg Si1e" The leg size show above is what is re)uired. For cost calculatios #06 is added to the size show. This is cosistat with or!al shop practices. Flat Cove: English Units Metric Units Choose Units For This Sh... Stainless Steel Carbon Steel GMAW (98Ar-2O2) GMAW CO2 90Ar-10Co2 Co2 35% 35% WELDING COST OUTPUT FOR A FILLET WELD O5T&5T .O! 4-)W CO2 &!out of filler !etal eeded ID&;?,J kg Ku!ber of passes per 'oit L ID&;?,J 8ize of fillet weldMM ..N.B !! &!out of shieldig gas used ID&;?,J !G$ Ku!ber of 9as >ottles Ce)uired ID&;?,J &ctual weldig ti!e ID&;?,J hr ;abor Cost ID&;?,J +eldig ,lectrode Cost ID&;?,J 9as Cost ID&;?,J Flu: Cost F 3 5ower Cost ID&;?,J Iitial Cost ID&;?,J Fial Cost =V)L5E> Total cost per !eter of weld ID&;?,J F(! Filler cost per !eter of weld ID&;?,J F(! Flu: cost per !eter of weld 3 F(! 9as cost per !eter of weld ID&;?,J F(! ;abor cost per !eter of weld ID&;?,J F(! MM 8ize of the fillet weld is based o heat iput. This ifor!atio ca be used to ad'ust your a!ps O volts to achieve the leg size you etered i Cell >#0 O5T&5T .O! 4-)W 2?@)r"2O23 &!out of filler !etal eeded ID&;?,J kg Ku!ber of passes per 'oit L ID&;?,J 8ize of fillet weldMM 0.0-E !! &!out of shieldig gas ID&;?,J !G$ Ku!ber of 9as >ottles Ce)uired ID&;?,J &ctual weldig ti!e ID&;?,J hr ;abor Cost ID&;?,J +eldig ,lectrode Cost ID&;?,J 9as Cost ID&;?,J Flu: Cost F 3 5ower Cost ID&;?,J Iitial Cost ID&;?,J Fial Cost =V)L5E> Total cost per !eter of weld ID&;?,J F(! Filler cost per !eter of weld ID&;?,J F(! Flu: cost per !eter of weld 3 F(! 9as cost per !eter of weld ID&;?,J F(! ;abor cost per !eter of weld ID&;?,J F(! ;abor Cost +eldig ,lectrode Cost 9as Cost Flu: Cost 5ower Cost ;abor Cost +eldi g ,lectrode Cost 9as Cost Fl u: Cost 5ower Cost =V)L5E> &roides ) =V)L5E> Saings !elatie To The =V)L5E> ;abor Cost +eldi g ,lectrode Cost 9as Cost Fl u: Cost 5ower Cost Weld Cost CalcAL +ritte >y" 'ark (. 'ruc)ek Copyright *++* 'ark (. 'ruc)ek 5pdates since inception =ate Chage #B3May302 Added ,pdate Sheet Check Spelling Checked Against Sa#ple Calculations .3Feb30$ Added Co#pound Single -evel .oint to the spreadsheet 'oved all calculations to a separate page A3@ul30$ Added $ouble/01 and $ouble -evel joint to the spreadsheet Sa#ple 0alues Entered #03<ct30$ Added ,nits page Added units conversion 0- code to each sheet #N3@a30- Added Single/,1 Single/.1 and $ouble/. .oints to the spreadsheet ,pdated all weld joint drawing using Arc Works drawing software (ro# the Lincoln Electric co#pany ,pdated %ables page to add #ore base #etals1 gases and welder efficiencies 2N3&pr30- Corrected errors in cost calculations 2rotected Spreadsheet E3&ug30. Added $eposition rate page to the spreadsheet Corrected errors in unit conversion calculations in 0- code ,pdated Weld .oint $rawings Sa#ple Calcs &an/0erification Co#plete Added 3otes to (illet weld page and fillet weld drawing showing flat and conve4 beads #2((#-(200. Changed 3a#e fro# Weld Cost &ev 5 to Weld Cost Calc6L $03@a30. (iled for Copyright ,pdated all weld joint drawing using Arc Works drawing software (ro# the Lincoln Electric co#pany