BIZOMAT MAKEOS · Fabrication
Fillet Weld Cost per Metre
What does this fillet weld cost per metre in labour, filler and gas?
Weld metal mass, arc time, labour, filler metal and shielding gas cost per metre of fillet weld from leg size, deposition rate, operating factor and prices.
Open the calculatorRuns in your browser. No account needed.
How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Fillet leg size | mm | Specified leg length of an equal-leg fillet. |
| Excess weld (reinforcement and overwelding) | % | Extra metal from convexity and oversize welds (often 10–30%). |
| Weld metal density | g/cm³ | Density of the deposited metal. |
| Deposition rate | kg/h | Deposition rate for the process, wire size and current (from the consumable maker). |
| Operating factor (arc-on share) | % | Share of the welder’s paid time with the arc on (manual 20–40%, mechanised more). |
| Deposition efficiency | % | Share of filler bought that ends up as weld metal (solid MIG wire about 90–95%, stick electrodes about 60–65%). |
| Labour and overhead rate | AUD/h | Fully loaded labour and overhead cost per hour. |
| Filler price | AUD/kg | Filler metal price per kilogram. |
| Gas flow (0 for no gas) | L/min | Shielding gas flow rate. |
| Gas price | AUD/m³ | Gas cost per cubic metre. |
What each input means
Open an input to see what it is, its units, the worked example and the common mistakes, with a small diagram.
What this means: Fillet leg size
- What it is
- The specified leg length of an equal-leg fillet weld, the distance from the root to the toe along each plate.
- Units and format
- Enter a number in mm: millimetres. The form accepts 0.000001 mm to 100 mm. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 6 mm as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Weld metal, and so most of the cost, rises with the square of the leg size.
- Get it right
- Use the leg length, not the throat; the throat is smaller.
What this means: Excess weld (reinforcement and overwelding)
- What it is
- The extra weld metal deposited beyond the ideal triangular fillet, from convexity and welds made oversize.
- Units and format
- Enter a number in %: percent: the number is read as a percentage, so type 8 for 8 %. The form accepts 0% to 200%. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 15% as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Weld metal mass, time and every cost rise in proportion to one plus this allowance.
- Get it right
- Type the percentage (15 for 15 %); measure real welds or use your shop history.
What this means: Weld metal density
- What it is
- The density of the deposited weld metal, used to turn the weld cross-section into mass per metre.
- Units and format
- Enter a number in g/cm³: grams per cubic centimetre (1 g/cm³ = 1000 kg/m³). The form accepts 0.000001 g/cm³ to 25 g/cm³. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 7.85 g/cm³ as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Weld mass and all costs rise in proportion to density.
- Get it right
- Enter grams per cubic centimetre, not kilograms per cubic metre.
What this means: Deposition rate
- What it is
- The mass of weld metal deposited per hour of arc-on time for the process, wire size and current, from the consumable maker or your trials.
- Units and format
- Enter a number in kg/h: kg/h. The form accepts 0.000001 kg/h to 100 kg/h. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 3 kg/h as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Arc time, labour and gas cost fall in inverse proportion to the deposition rate.
- Get it right
- This is per hour of arc time, not per hour of paid time.
What this means: Operating factor (arc-on share)
- What it is
- The share of the welder’s paid time that the arc is actually on, after setting up, fitting, cleaning and moving between welds.
- Units and format
- Enter a number in %: percent: the number is read as a percentage, so type 8 for 8 %. The form accepts 1% to 100%. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 30% as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Paid time and labour cost fall in inverse proportion to the operating factor.
- Get it right
- Type the percentage (30 for 30 %); measure it on the shop floor for quoting.
What this means: Deposition efficiency
- What it is
- The share of filler metal bought that ends up in the weld, after spatter, stub ends and slag.
- Units and format
- Enter a number in %: percent: the number is read as a percentage, so type 8 for 8 %. The form accepts 1% to 100%. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 92% as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Filler cost falls in inverse proportion to deposition efficiency.
- Get it right
- Type the percentage; take it from the consumable maker for the process.
What this means: Labour and overhead rate
- What it is
- The fully loaded cost of one hour of welder time, including wages, on-costs and the workshop overhead your costing assigns.
- Units and format
- Enter a number in AUD/h: Australian dollars per hour. The form accepts 0 AUD/h to 100000 AUD/h. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 95 AUD/h as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Labour cost rises in proportion to the rate.
- Get it right
- Use the loaded rate from your finance team, not just the wage.
What this means: Filler price
- What it is
- The price paid for one kilogram of filler wire or electrodes, from your supplier’s invoice.
- Units and format
- Enter a number in AUD/kg: money per kg. The form accepts 0 AUD/kg to 100000 AUD/kg. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 6 AUD/kg as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Filler cost rises in proportion to the price.
What this means: Gas flow (0 for no gas)
- What it is
- The shielding gas flow set on the regulator while the arc is on; zero for processes without gas, such as stick welding.
- Units and format
- Enter a number in L/min: litres per minute. The form accepts 0 L/min to 1000 L/min. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 15 L/min as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Gas cost rises in proportion to flow.
- Get it right
- Enter litres per minute; gas is counted only during arc time.
What this means: Gas price
- What it is
- The cost of one cubic metre of shielding gas, including cylinder rental if you want it in the cost.
- Units and format
- Enter a number in AUD/m³: money per m³. The form accepts 0 AUD/m³ to 100000 AUD/m³. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 12 AUD/m³ as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Gas cost rises in proportion to the price.
- Get it right
- One cubic metre is 1000 litres; check whether your supplier prices per cubic metre or per cylinder.
Method and formulas
- Weld metal = ½ × leg² × (1 + excess) × density (kg/m).
- Arc time = mass ÷ deposition rate; paid time = arc time ÷ operating factor.
- Labour = paid time × rate; filler = mass ÷ efficiency × price; gas = arc time × flow × price.
- Example: a 6 mm fillet costs about $18.80 per metre, mostly labour.
Limitations
- Excludes preparation, fit-up, cleaning, inspection and distortion correction.
- Deposition rate and operating factor vary greatly between shops; use measured values.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Quote welded fabrication
- Compare processes and weld sizes
- Show the cost of oversize welds
Who it is for
- Fabrication supervisors
- Manufacturing engineers
- Estimators
What you get
- Weld metal per metre
- Arc time and paid time per metre
- Labour, filler and gas cost per metre
- Total cost per metre
Interpreting the result
- Weld cost rises with the square of leg size: avoid specifying welds larger than needed.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 1439–1441, 1429–1449. Topic reference; no source tables or recommended settings are reproduced.
BIZOMAT 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.