DETERMINING WELDING COST FOR A FILLET WELD

Mark Mruczek Project: Base Material: A 516 Date: 08/07/02Welding Engineer Company: Product Form: Plate Page: 1 of 2

Subject: Welding Cost Filler MaterialWelding process Used: Trade Name:

Process 1 Process 2Leg Size (in) 0.250 Leg Size (in) 0.250

Filler material Filler material

Process ProcessGas Used Gas Used

Amps 200 Amps 200Volts 21 Volts 21

Wire Feed (in/min) 0 Wire Feed (in/min) 190Wire Diam. (in) 0.187 Wire Diam. (in) 0.045Total Length of Weld(ft) 10 Total Length of Weld(ft) 10Travel Speed (ipm) 6 Travel Speed (ipm) 8Gas Flow Rate (cfh) 0 Gas Flow Rate (cfh) 40Welder Efficiency 30% Welder Efficiency 50%Cost Electrode($/lb) 1.3 Cost Electrode($/lb) 2.5Labor Rate ($/hr) 60 Labor Rate ($/hr) 60Cost of Gas (per bottle) $0.00 Cost of Gas (per bottle) $70.00Weight of gas (1 bottle) (lb) 0 Weight of gas (1 bottle) (lb) 50Power Cost ($/kilowatt-hr) $0.15 Power Cost ($/kilowatt-hr) $0.15

WELDING COST OUTPUT FOR A FILLET WELD OUTPUT FOR PROCESS 1 SMAW (14" Stick)Amount of weld wire needed 2.00 lbNumber of passes per joint ~ 1Size of fillet weld** 0.290 inAmount of shielding gas 0.00 ft^3 bottles = N/AActual welding time 1.80 hr

Labor Cost $108.15Welding Wire Cost $2.60Gas Cost $0.00Power Cost $0.35Initial Cost $111.10Final Cost $127.80

Cost per ft of weld $11.11 $/ftCost per foot filler metal $0.26 $/ftCost per foot of gas $0.00 $/ftCost of Labor per foot $10.82 $/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 B10OUTPUT FOR PROCESS 2 FCAW (Gas)Amount of weld wire needed 2.00 lbNumber of passes per joint ~ 1Size of fillet weld** 0.251 inAmount of shielding gas 0.00 ft^3 bottles = 1Actual welding time 0.78 hr

Labor Cost $46.80Welding Wire Cost $5.00Gas Cost $2.55Power Cost $0.25Initial Cost $54.60Final Cost $62.80

Cost per ft of weld $5.46 $/ft

Labor Cost97%

Welding Wire Cost2%

Power Cost0%

Labor CostWelding Wire CostGas CostPower Cost

Labor Cost86%

Welding Wire Cost9%

Gas Cost5%

Power Cost0%

Labor CostWelding Wire CostGas CostPower Cost

Cost per foot filler metal $0.50 $/ftCost per foot of gas $0.26 $/ftCost of Labor per foot $4.68 $/ft

Labor Cost86%

Welding Wire Cost9%

Gas Cost5%

Power Cost0%

Labor CostWelding Wire CostGas CostPower Cost

Labor Cost97%

Welding Wire Cost2%

Power Cost0%

Labor CostWelding Wire CostGas CostPower Cost

DETERMINING WELDING COST FOR A SINGLE-V GROOVE WELD

Mark Mruczek Project: Base Material: A 516 Date: 08/07/02Welding Engineer Company: Product Form: Plate Page: 1 of 2

Subject: Welding Cost Filler Material E7018Welding process Used: Trade Name:

Process 1 Process 2Thickness (in) 0.625 Thickness (in) 0.625

Height of "h" (in) 0.063 Height of "h" (in) 0.063Root Opening (in) 0.094 Root Opening (in) 0.094

Root Face(in) 0.063 Root Face(in) 0.063

Filler material Filler material

Process ProcessGas Used Gas Used

Amps 200 Amps 200Volts 22 Volts 20

Wire Feed (in/min) 0 Wire Feed (in/min) 225Wire Diam. (in) 0.1875 Wire Diam. (in) 0.05

Joint Angle 60 Joint Angle 60Total Length of Weld(ft) 1000 Total Length of Weld(ft) 1000Travel Speed (ipm) 6 Travel Speed (ipm) 8Gas Flow Rate (cfh) 0 Gas Flow Rate (cfh) 35Welder Efficiency 30% Welder Efficiency 50%Cost Electrode($/lb) 1.26 Cost Electrode($/lb) 2.25Labor Rate ($/hr) 60 Labor Rate ($/hr) 60Cost of Gas (per bottle) $0.00 Cost of Gas (per bottle) $75.00Weight of gas in one bottle ( 0 Weight of gas in one bottle (l 50Power Cost ($/kilowatt-hr) $0.10 Power Cost ($/kilowatt-hr) $0.12

WELDING COST OUTPUT FOR A SINGLE-V GROOVE WELD

OUTPUT FOR SMAW (14" Stick)Amount of weld wire needed 1492.13 lbNumber of passes per joint ~ 6Amount of shielding gas 0.00 ft^3 bottles = N/AActual welding time 1344.26 hr

Labor Cost $50,006.52Welding Wire Cost $1,880.08Gas Cost $0.00Power Cost $177.44Initial Cost $52,064.05Final Cost $59,873.65

Cost per ft of weld $52.06 $/ftCost per foot filler metal $1.88 $/ftCost per foot of gas $0.00 $/ftCost of Labor per foot $50.01 $/ft

OUTPUT FOR FCAW (Gas)Amount of weld wire needed 1075.72 lbNumber of passes per joint ~ 9Amount of shielding gas 6196.31 ft^3 bottles = 14Actual welding time 354.07 hr

Labor Cost $18,270.25Welding Wire Cost $2,420.37Gas Cost $1,068.86Power Cost $84.98Initial Cost $21,844.47Final Cost $ 25,121.13

Cost per ft of weld $21.84 $/ftCost per foot filler metal $2.42 $/ftCost per foot of gas $1.07 $/ft

Labor Cost84%

Welding Wire Cost11%

Gas Cost5%

Power Cost0%

Labor CostWelding Wire CostGas CostPower Cost

Labor Cost96%

Welding Wire Cost4%

Power Cost0%

Labor Cost

Welding Wire Cost

Gas Cost

Power Cost

Cost of Labor per foot $18.27 $/ft

Labor Cost84%

Welding Wire Cost11%

Gas Cost5%

Power Cost0%

Labor CostWelding Wire CostGas CostPower Cost

DETERMINING WELDING COST FOR A SINGLE-BEVEL GROOVE WELD

Mark Mruczek Project: Base Material: A 516 Date: 05/22/02Welding Engineer Company: Product Form: Plate Page: 1 of 2

Subject: Welding Cost Filler Material E7018Welding process Used: SMAW + GMAW Trade Name: Lincoln

Process 1 Process 2Thickness (in) 2.25 Thickness (in) 2.25

Height of "h" (in) 0.09375 Height of "h" (in) 0.09375Root Opening (in) 0.125 Root Opening (in) 0.125

Root Face(in) 0.09375 Root Face(in) 0.09375

Filler material Filler material

Process ProcessGas Used Gas Used

Amps 200 Amps 175Volts 21 Volts 20

Wire Feed (in/min) 225 Wire Feed (in/min) 0Wire Diam. (in) 0.052 Wire Diam. (in) 0.188

Joint Angle 45 Joint Angle 45Total Length of Weld(ft) 3.535 Total Length of Weld(ft) 3.535Travel Speed (ipm) 9 Travel Speed (ipm) 5.5Gas Flow Rate (cfh) 35 Gas Flow Rate (cfh) 0Welder Efficiency 50% Welder Efficiency 30%Cost Electrode($/lb) 2.45 Cost Electrode($/lb) 1.3Labor Rate ($/hr) 50 Labor Rate ($/hr) 50Cost of Gas (per bottle) $50.00 Cost of Gas (per bottle) $0.00Weight of gas in one bottle 50 Weight of gas in one bottle (l 0Power Cost ($/kilowatt-hr) $0.15 Power Cost ($/kilowatt-hr) $0.15

WELDING COST OUTPUT FOR A SINGLE-BEVEL GROOVE WELD

OUTPUT FOR FCAW (Gas)Amount of weld wire needed 38.37 lbNumber of passes per joint ~ 100Amount of shielding gas 165.52 ft^3 bottles = 1Actual welding time 9.46 hr

Labor Cost $406.70Welding Wire Cost $94.01Gas Cost $19.03Power Cost $2.98Initial Cost $522.72Final Cost $ 601.13

Cost per ft of weld $147.87 $/ftCost per foot filler metal $26.59 $/ftCost per foot of gas $5.38 $/ftCost of Labor per foot $115.05 $/ft

OUTPUT FOR SMAW (14" Stick)Amount of weld wire needed 54.00 lbNumber of passes per joint ~ 73Amount of shielding gas 0.00 ft^3 bottles = N/AActual welding time 60.00 hr

Labor Cost $3,000.00Welding Wire Cost $70.20Gas Cost $0.00Power Cost $0.28Initial Cost $3,081.00Final Cost $ 3,543.15

Labor Cost78%

Welding Wire Cost18%

Gas Cost4%

Power Cost1% Labor Cost

Welding Wire Cost

Gas Cost

Power Cost

Labor Cost98%

Welding Wire Cost2%

Power Cost0%

Labor Cost

Welding Wire Cost

Gas Cost

Power Cost

Cost per ft of weld $871.57 $/ftCost per foot filler metal $19.86 $/ftCost per foot of gas $0.00 $/ftCost of Labor per foot $848.66 $/ft

Labor Cost98%

Welding Wire Cost2%

Power Cost0%

Labor Cost

Welding Wire Cost

Gas Cost

Power Cost

CALCULATIONS PROCESS 1 Single-V Groovedistance "d" = 0.5625 in Process Efficiency 62% Process SMAW (14" Stick)Distance "R" = 0.6495 in Welder Efficiency 30% Bottles of gas needed N/ADistance c1 = 0.6495 in Arc Time 403.28 hr Radius of cap "r" 1.136146Distance "c" = 0.7433 in Total welding time 1344.26 hr Deposited Weld Metal Wt. 925Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0 lb/ft^3Area Cap "C" 0.0311 in^2 Volume of gas in one 0.00 ft^3Weld Metal Weight "C" 0.1058 lb/ft bottleArea Rectangle "A" 0.0586 in^2 Total gas needed 0.00 ft^3Weld Metal Weight "A" 0.199 lb/ft Labor Cost $ 50,006.52 Area of two Triangles "B" 0.1827 in^2 Gas Cost $0.00Weld Metal Weight "B" 0.620 lb/ft Cost Electrode $1,880.08Total Weld Metal Weight 0.9251 lb/ft Total Cost $ 52,064.05 Amount of Welding Wire 1492.13 lb Final Cost $ 7,809.61 $ 59,873.65 Deposition Rate 3.70 Lb/hr Heat Input 44Total Power Cost $177.44 Number of Passes 6

CALCULATIONS PROCESS 2 Single-V Groovedistance "d" = 0.5625 in Process Efficiency 86% Process FCAW (Gas)Distance "R" = 0.6495 in Welder Efficiency 50% Bottles of gas needed 14Distance c1 = 0.6495 in Arc Time 177.04 hr Radius of cap "r" 1.136146Distance "c" = 0.7433 in Total welding time 354.07 hr Deposited Weld Metal Wt. 925.1206Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0.115 lb/ft^3Area Cap "C" 0.0311 in^2 Volume of gas in one 434.78 ft^3Weld Metal Weight "C" 0.1058 lb/ft bottleArea Rectangle "A" 0.0586 in^2 Total gas needed 6196.31 ft^3Weld Metal Weight "A" 0.199 lb/ft Labor Cost $ 18,270.25 Area of two Triangles "B" 0.1827 in^2 Gas Cost $1,068.86Weld Metal Weight "B" 0.620 lb/ft Cost Electrode $2,420.37Total Weld Metal Weight 0.9251 lb/ft Total Cost $ 21,844.47 Amount of Welding Wire 1075.72 lb Final Cost $ 3,276.67 $ 25,121.13 Deposition Rate 6.08 Lb/hr Heat Input 30Total Power Cost $84.98 Number of Passes 9

CALCULATIONS PROCESS 1 Single-Bevel Groovedistance "d" = 2.15625 in Process Efficiency 86% Process FCAW (Gas)Distance "R" = 3.0494 in Welder Efficiency 50% Bottles of gas needed 1Distance c1 = 2.1563 in Arc Time 4.73 hr Radius of cap "r" 6.986Distance "c" = 2.2813 in Total welding time 9.46 hr Beta 45Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0.115 lb/ft^3 Deposited Weld Metal Wt. 33.00Area Cap "C" 0.1428 in^2 Volume of gas in one 434.78 ft^3Weld Metal Weight "C" 0.4848 lb/ft bottleArea Rectangle "A" 0.2813 in^2 Total gas needed 165.52 ft^3Weld Metal Weight "A" 0.955 lb/ft Labor Cost $ 406.70 Area of two Triangles "B" 2.3247 in^2 Gas Cost $19.03Weld Metal Weight "B" 7.895 lb/ft Cost Electrode $94.01Total Weld Metal Weight 9.335 lb/ft Total Cost $ 522.72 Amount of Welding Wire 38.37 lb Final Cost $ 78.41 $ 601.13 Deposition Rate 8.11 Lb/hr Heat Input 28Total Power Cost $2.98 Number of Passes 100

CALCULATIONS PROCESS 2 Single-Bevel Groovedistance "d" = 2.15625 in Process Efficiency 62% Process SMAW (14" Stick)Distance "R" = 3.0494 in Welder Efficiency 30% Bottles of gas needed N/ADistance c1 = 2.1563 in Arc Time 18.00 hr Radius of cap "r" 6.986Distance "c" = 2.2813 in Total welding time 60.00 hr Beta 45Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0 lb/ft^3 Deposited Weld Metal Wt. 33.00Area Cap "C" 0.1428 in^2 Volume of gas in one 0.00 ft^3Weld Metal Weight "C" 0.4848 lb/ft bottleArea Rectangle "A" 0.2813 in^2 Total gas needed 0.00 ft^3Weld Metal Weight "A" 0.955 lb/ft Labor Cost $ 3,000.00 Area of two Triangles "B" 2.3247 in^2 Gas Cost $0.00Weld Metal Weight "B" 7.895 lb/ft Cost Electrode $70.20Total Weld Metal Weight 9.335 lb/ft Total Cost $ 3,081.00 Amount of Welding Wire 54.00 lb Final Cost $ 3,543.15 Deposition Rate 3.000 Lb/hr Heat Input 38.18181818Total Power Cost $10.80 Number of Passes 73

CALCULATIONS PROCESS 1 Fillet WeldArea of Fillet Weld 0.0313 Process Efficiency 62%in2

Volume of Weld Metal 3.750 Welder Efficiency 30%0.283 Arc Time 0.541 hr

Total Weld Metal Weight 0.106 lb/ft Total welding time 1.802 hrAmount of Welding Wire 2.000 lb Heat Input 42 kJ/inDeposition Rate 3.700 lb/hr Fillet Weld Size 0.290 inDensity of gas 0 Number of Passes 1Volume of gas in one 0 Labor Cost $108.15bottle Gas Cost $0.00Total gas needed 0 Cost Electrode $2.60Bottles of gas needed N/A Total Power Cost $0.35Process SMAW (14" Stick) Total Cost $111.10

Final Cost $127.80

CALCULATIONS PROCESS 2 Fillet WeldArea of Fillet Weld 0.0313 Process Efficiency 86%Volume of Weld Metal 3.750 Welder Efficiency 50%

0.283 Arc Time 0.390 hrTotal Weld Metal Weight 0.106 lb/ft Total welding time 0.780 hrAmount of Welding Wire 2.000 lb Heat Input 31.5 kJ/inDeposition Rate 5.1310494 lb/hr Fillet Weld Size 0.251 inDensity of gas 0.116 Number of Passes 1Volume of gas in one 431.034483 Labor Cost $46.80bottle Gas Cost $2.55Total gas needed 15.5913525 Cost Electrode $5.00Bottles of gas needed 1 Total Power Cost $0.25Process FCAW (Gas) Total Cost $54.60

Final Cost $62.80

in3

Filler Density lb/in3 lb/in3

lb/ft3

ft3

ft3

in2

in3

Filler Density lb/in3 lb/in3

lb/ft3

ft3

ft3

SMAW (14" Stick)

inlb

FCAW (Gas)

inlb

FCAW (Gas)

in

lb

SMAW (14" Stick)

in

lb

Alloy Density Process&Welder Eff (%) GAS Densities Cap HieghtCarbon Steel 0.283 SAW 99% 70% N/A 0 0Stainless Steel 0.29 GMAW (98Ar-2O2) 98% 50% Ar 0.111 0.03125

Nickel Alloy 0.31 GMAW (75Ar-25CO2) 96% 50% Co2 0.116 0.063GMAW CO2 93% 50% C25 0.115 0.094

1 1 FCAW (Gas) 86% 50% 1 4 Single V 0.1251 1 FCAW (Self Shield) 78% 50% 4 1 Single Bev 0.251 1 SMAW (12" Stick) 59% 30% 1 3 Fillet 0.375

SMAW (14" Stick) 0.62 30% 2SMAW (18" Stick) 66% 30% 3

8 5 Sing-V 35 8 Sing-Bev 38 5 Fillet 4

Interpolation of Deposit Single_V Interpolation of Deposit 3Rate Process 1 5 Deposition Rates SMAW 8 Rate Process 1

0.000 0 110 1.8 0 0.0000.000 0 125 2 0 0.0000.000 0 150 2.6 0 0.0000.000 0 175 3 0 0.0006.076 200 200 3.7 200 3.7000.000 0 225 4.2 0 0.0000.000 0 275 7 0 0.0000.000 0 325 9 0 0.0006.076 400 10 3.700

Weld Size0.125 Interpolation of Deposit Single Bevel Interpolation of Deposit

0.1875 Rate Process 1 8 Deposition Rates SMAW 5 Rate Process 10.250 0.000 0 110 1.8 0 0.0000.313 0.000 0 125 2 0 0.0000.375 0.000 0 150 2.6 0 0.0000.438 3.000 175 175 3 0 0.0000.500 0.000 0 200 3.7 200 8.114

0.5625 0.000 0 225 4.2 0 0.0000.625 0.000 0 275 7 0 0.0000.688 0.000 0 325 9 0 0.0000.750 3.000 400 10 8.114

0.81250.875 Interpolation of Deposit Fillet Weld Interpolation of Deposit 0.938 Rate Process 1 8 Deposition Rates SMAW 5 Rate Process 11.000 0.000 0 110 1.8 0 01.125 0.000 0 125 2 0 0

1.25 0.000 0 150 2.6 0 01.375 0.00 0 175 3 0 0

1.5 3.700 200 200 3.7 200 5.1311.5625 0.000 0 225 4.2 0 0

1.625 0.000 0 275 7 0 01.75 0.000 0 325 9 0 0

1.8125 3.700 400 10 5.1311.875

22.125

2.252.375

2.52.5625

2.6252.75

2.81252.875

33.125

3.253.375

3.53.5625

3.6253.75

3.8125Single V 9 9Single Bevel 27 27Fillet Weld 3 3

322343