How to use this calculator
- Enter weld length and area. Use the total weld length and deposited cross-section area from the drawing or weld takeoff.
- Enter deposition data. Set metal density, deposited metal rate and deposition efficiency for the process.
- Enter shop costs. Add filler price, waste allowance, labor/shop rate, labor time factor and overhead.
- Read per-length cost. Use cost per inch, cost per foot, total cost and bucket splits for quoting or comparison.
How it works
Weld cost starts with deposited metal quantity. The calculator uses the entered weld area and length:
V = A x L
m_deposited = V x density
Filler mass adjusts for deposition efficiency and a waste allowance:
m_filler = m_deposited / eta x (1 + waste)
Arc time uses the deposited metal rate. Labor time is the entered multiplier on arc time, so the worksheet can include fit-up, cleaning and handling:
t_arc = m_deposited / deposition_rate
cost = (filler_cost + labor_cost) x (1 + overhead)
Worked example
Verified against the live calculator
A 1 m weld with 18 mm^2 area has
18 cm^3 of deposited metal. With steel density,
2 kg/h deposited rate, 85% efficiency,
10% filler waste, $8/kg filler,
$95/hr labor, 2x labor factor and
15% overhead, the total estimate is about
$18, or about $0.46 per inch.
Frequently asked questions
How do you calculate weld cost per inch?
Estimate weld volume from cross-section area times length, convert volume to deposited mass, estimate arc time from deposition rate, then add filler cost and labor cost before dividing by weld length.
What should I use for weld cross-section area?
Use the area from a weld drawing, the groove weld area calculator, or a fillet estimate such as 0.5 x leg size squared per side. Add an overweld or cap allowance if your shop consistently deposits more metal.
Why is labor time higher than arc time?
Arc time is only time with the arc on. The labor time factor lets you include handling, fit-up, cleaning, repositioning, starts/stops, inspection support and other direct shop time.
Does this include shielding gas, power or inspection?
No. This is a direct labor and filler-metal screen. Add shielding gas, power, fixtures, NDE, qualification, travel, taxes and risk separately when quoting production work.
Method & assumptions
- Weld cross-section area should include the geometry and overweld/cap allowance you want to quote.
- Deposition rate, efficiency, filler price, labor rate and overhead are all user-entered; there is no live material or wage lookup.
- Arc time is arc-on time only. The labor time factor is the only allowance for fit-up, cleaning, repositioning, pass changes, handling and inspection support.
- Use welding deposition, groove weld area, wire feed speed, welding duty cycle and welding amperage for adjacent setup and takeoff checks.