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Legal Statement Year 2006 release

Copyright 2002 Mark F. Mruczek


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
&lthough 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%
SINGLE - V GROOVE
FILLET WELD
SINGLE BEVEL DOUBLE-V GROOVE
=ouble >evel
8igle3?
8igle3@
=ouble3@
Co!poud 8igle3>evel =ouble3?
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 0.2.0 i Leg Si1e 2in3 0.2. i
.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 2in6min3 -B0 i(!i Wire .eed 2in6min3 -B0 i(!i
Electrode $iam7 2in3 0.0-. i Electrode $iam7 2in3 0.0-. i
Total Length of Weld 2ft3 20000 ft Total Length of Weld 2ft3 20000 ft
Trael Speed 2in6min3 ##.0 i(!i Trael Speed 2in6min3 ##.0 i(!i
4as .lo% !ate 2ft896hr3 $0 ftE$(hr 4as .lo% !ate 2ft896hr3 $0 ftE$(hr
Welder Efficiency Welder Efficiency
Cost Electrode 2:6lb3 2... F(lb Cost Electrode 2:6lb3 2... F(lb
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 2ft893 $$0 ftE$ 4as Cylinder Si1e 2ft893 $$0.00 ftE$
&o%er Cost 0.20 F(kwh &o%er Cost 0.20 F(kwh
Cost of .l'; 2:6lb3 3 F(lb Cost of .l'; 2:6lb3 3 F(lb
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 G #
;ast # Scroll $own %o See &esults
Company, /!EC
S'b+ect, Welding Cost < Time
Welding process2es3 5sed, 4-)W
Leg Si1e" The leg size show above is what is re)uired. For cost calculatios #06 is added to the size show. This is cosistat with or!al shop practices.
English Units Metric Units
Choose Units
For This Sh...
Flat
Cove:
Carbon Steel Carbon Steel
GMAW (98Ar-2O2) GMAW (98Ar-2O2)
90Ar-10Co2
90Ar-10Co2
35% 35%
WELDING COST OUTPUT FOR A FILLET WELD
O5T&5T .O! 4-)W 2=>)r"2O23
&!out of filler !etal eeded HD&;?,I lbs
Ju!ber of passes per 'oit K HD&;?,I
8ize of fillet weldLL 0.2-A i
&!out of shieldig gas used HD&;?,I ftE$
Ju!ber of 9as >ottles Ce)uired HD&;?,I
&ctual weldig ti!e HD&;?,I hr
;abor Cost HD&;?,I
+eldig ,lectrode Cost HD&;?,I
9as Cost HD&;?,I
Flu: Cost F 3
5ower Cost HD&;?,I
Iitial Cost HD&;?,I
Fial Cost ?V)L5E@
Total cost per ft of weld HD&;?,I F(ft
Filler cost per ft of weld HD&;?,I F(ft
Flu: cost per ft of weld 3 F(ft
9as cost per ft of weld HD&;?,I F(ft
;abor cost per ft of weld HD&;?,I F(ft
LL 8ize of the fillet weld is based o heat iput. This ifor!atio ca be used to ad'ust your a!ps M volts to achieve the leg size you etered i Cell >#0
O5T&5T .O! 4-)W 2=>)r"2O23
&!out of filler !etal eeded HD&;?,I lbs
Ju!ber of passes per 'oit K HD&;?,I
8ize of fillet weldLL 0.2-A i
&!out of shieldig gas HD&;?,I ftE$
Ju!ber of 9as >ottles Ce)uired HD&;?,I
&ctual weldig ti!e HD&;?,I hr
;abor Cost HD&;?,I
+eldig ,lectrode Cost HD&;?,I
9as Cost HD&;?,I
Flu: Cost F 3
5ower Cost HD&;?,I
Iitial Cost HD&;?,I
Fial Cost ?V)L5E@
Total cost per ft of weld HD&;?,I F(ft
Filler cost per ft of weld HD&;?,I F(ft
Flu: cost per ft of weld 3 F(ft
9as cost per ft of weld HD&;?,I F(ft
;abor cost per ft of weld HD&;?,I F(ft
;abor Cost
+eldig ,lectrode Cost
9as Cost
Flu: Cost
5ower Cost
;abor Cost
+eldig ,lectrode Cost
9as Cost
Flu: Cost
5ower Cost
?V)L5E@ &roides ) ?V)L5E@ Saings !elatie To The ?V)L5E@
;abor Cost
+eldig ,lectrode Cost
9as Cost
Flu: 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
O3&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